M6610 A

TRAINING MANUAL

AVTEC LTD
POWER PRODUCTS DIVISION
NEAR POOANAPLLI VILLAGE
HOSUR-635114, TAMIL NADU
TEL: 04344 405200

INFO REGARDING THE TRANSMISSION:

1
2
3
4
5

Name of the Transmission

Name Plate
1st two digits
Next two digits
Next four digits

6
7
8

Speeds
Oil Grade
Oil Capacity

M6610 A
Lower side of the rear cover
Product Code
31
Manufacturing plant source
60
Serial number for that particular model 1234
Example: 31 60 1234
6-Forward & 2-Reverse
C 4 SAE 30
65-70 litres

TECHNICAL SPECIFICATIONS:
1 Net Input Power
2 Input Speed
3 Net Input Torque

710 nhp ( 529 KW)

2500 rpm
2270 lb Ft (3078Nm)

INFO REGARDING PRESSURES:

Main Pressure

2 Converter Out Pressure

3 Lubrication Pressure
4 Normal Operating Temperature

150-220 psi
30 to 60 psi
20 psi minimum
180 to 220 F

LEGEND DETAILS

1. Input flange
2. Input shaft
3. Torque converter drive housing
4. Front cover
5. Lock up clutch
6. Torque converter housing
7. Torque converter turbine
8. Torque converter stator
9. Torque converter pump
10.Flex plate drive assembly
11.Fly wheel
12.Lock up clutch
13.Torque converter housing
14.Torque converter turbine
15.Torque converter stator
16.Torque converter pump
17.Power take off cover
18.Power take off gear
19.Hydraulic retarder housing
20.Hydraulic retarder rotor
21.Turbine shaft
22.Governor(pitot)assembly
23.Splitter direct clutch ( low splitter)
24.Splitter over drive clutch( high splitter)
25.Splitter ring gear
26.Splitter planetary carrier
27.Fifth and sixth range clutch(high clutch)
28.Intermediate range planetary carrier
29.Third and fourth range clutch ( intermediate clutch)
30.First and second range clutch(low clutch)
31.Reverse clutch
32.Transmission rear cover(output drive housing)
33.Output shaft
34.Parking brake
35.Output flange
36.Speedometer drive gear
37.Speedometer driven gear
38.Reverse planetary carrier
39.Reverse ring gear
40.Reverse sun gear

41.Low range ring gear

42.Low range planetary carrier
43.Low range sun gear
44.Intermediate range planetary carrier
45.Intermediate range sun gear
46.Splitter sun gear
47.Input oil pump idler gear
48.Input oil pump drive gear(power take off drive)
49.Input and scavenge oil pump assembly
50.Input oil pump
51.Scavenge oil pump

CLUTCH COMBINATIONS:
SPEED RANGE
REVERSE 2
REVERSE 1

CLUTCH APPLIED
Splitter High and Reverse clutch
Splitter Low and Reverse clutch

NEUTRAL

Low Splitter

F1
F2
F3
F4
F5
F6

Forward 1
Forward 2
Forward 3
Forward 4
Forward 5
Forward 6

Splitter low and Low clutch

Splitter High and Low clutch
Splitter low and Intermediate clutch
Splitter High and Intermediate clutch
Splitter low and High clutch
Splitter High and High clutch

R2
R1

M6610 A FAULT CODES:

CODE
13 12
13 23
21 12
21 23
22 14
22 15
22 16
23 12
23 13
23 14
23 15
23 16
24 12
24 23
25 11
25 22
25 33
25 44
25 55
25 66
25 77
25 88
26 00
33 12
33 23
34 12
34 13
34 14
34 15
34 16
34 17

M6610A MODEL-FAULT CODES

REASON/EXPLANATION
ECU INPUT VOLTAGE LOW
ECU INPUT VOLTAGE HIGH
THROTTLE SENSOR FAILED LOW
THROTTLE SENSOR FAILED HIGH
ENGINE SPEED SENSOR
TURBINE SPEED SENSOR
OUT PUT SPEED SENSOR
PRIMARY SHIFT SELECTOR
PRIMARY SHIFT SELECTOR MODE FUNCTION
SECONDARY SHIFT SELECTOR
SECONDARY SHIFT SELECTOR MODE FUNCTION
SHIFT SELECTOR DISPLAY LINE FAULT
SUMP FLUID TEMPERATURE COLD
SUMP FLUID TEMPERATURE HOT
OUT PUT SPEED SENSOR , ZERO SPEED, 1 ST
OUT PUT SPEED SENSOR , ZERO SPEED, 2 ND
OUT PUT SPEED SENSOR , ZERO SPEED, 3 RD
OUT PUT SPEED SENSOR , ZERO SPEED, 4 TH
OUT PUT SPEED SENSOR , ZERO SPEED, 5 TH
OUT PUT SPEED SENSOR , ZERO SPEED, 6 TH
OUT PUT SPEED SENSOR , ZERO SPEED, 7 TH
OUT PUT SPEED SENSOR , ZERO SPEED, 8 TH
THROTTLE SOURCE NOT DETECTED
SUMP FLUID TEMPERATURE SENSOR FAILED LOW
SUMP FLUID TEMPERATURE SENSOR FAILED HIGH
FACTORY CAL COMPATIBILITY NUMBER WRONG
FACTORY CALIBRATION FAULT
POWER OFF FAULT
DIAGNOSTIC QUEUE FAULT
REAL TIME FAULT
CUSTOMER MODIFIABLE CONSTANTS FAULT

35 00
35 16
36 00
45 12
45 13
45 14
45 15
45 16
45 21
45 22
45 23
45 24
45 26
46 21
46 26
46 27
56 11
56 22
56 33
56 44
56 55
56 66
56 77
56 88
56 99
65 00
66 00
69 27
69 28
69 29
69 33
69 34
69 35
69 42
69 43

POWER INTERRUPTION
REAL TIME WRITE INTERRUPTION
HARDWARE/SOFTWARE NOT COMPATIBLE
GENERAL SOLENOID FAILURE-F
GENERAL SOLENOID FAILURE-K
GENERAL SOLENOID FAILURE-B
GENERAL SOLENOID FAILURE-G
GENERAL SOLENOID FAILURE-E
GENERAL SOLENOID FAILURE-H/J
GENERAL SOLENOID FAILURE-A
GENERAL SOLENOID FAILURE-D
GENERAL SOLENOID FAILURE-I
GENERAL SOLENOID FAILURE-C
HIGH SIDE OVER CURRENT, H/J SOLENOID
HIGH SIDE OVER CURRENT, C,D,E SOLENOID
HIGH SIDE OVER CURRENT, A,B,F,G,I,K SOLENOID
RANGE VERIFICATION RATIO TEST, 1ST
RANGE VERIFICATION RATIO TEST, 2ND
RANGE VERIFICATION RATIO TEST, 3RD
RANGE VERIFICATION RATIO TEST, 4TH
RANGE VERIFICATION RATIO TEST, 5TH
RANGE VERIFICATION RATIO TEST, 6TH
RANGE VERIFICATION RATIO TEST, R 1 OR 7TH
RANGE VERIFICATION RATIO TEST, R 2 OR 8TH
NETRAL VERIFICATION TEST RATIO
ENGINE RATING TOO HIGH YES
SCI ( SERIAL COMMUNICATIONS INTERFACE)
ECU INOPERATIVE A,B,F,G,I,K SOLENOID
ECU INOPERATIVE H/J SOLENOID
ECU INOPERATIVE C,D,E SOLENOID
ECU COP FAULT
ECU EEPROM FAULT
ECU EEPROM FAULT
SPI OUTPUT FAILURE
SPI INPUT FAILURE

TRANSMISSION OIL SPECIFICATION

MANUFACTURER

BRAND NAME

INDIAN OIL CORPORATION SERVO

LIMITED
TRANSMISSION

TYPE

C4-SAE 30

BHARATH PETROLEUM
CORPORATION LMTD

BHARAT HYDRAULIC
TRANSMISSION FLUID C4-SAE 30

HINDUSTAN PETROLEUM
CORPORATION LMTD

POWER GLIDE C-430

C4-SAE 30 ( C-430 )

TIDE WATER OIL

COMPANY(INDIA)

VEEDOL TRANS GEAR

C4-SAE 30

CHEMOLEUL PRIVATE
LIMITED

CHEMOLEUM
TRANSMISSION FLUID C4-SAE 30

GULF INDIA LIMITED

GULF HI FLUID

C4-SAE 30

CASTROL LIMITED

DEUSON TFC 430

C4-SAE 30

BALMER LAWRIEFUCHS
LIMITED

TITAN FLUX

C4-SAE 30 ( C4-30)

ELF LUBRICANTS LIMITED

TRANSELF

C4-SAE 30 ( C4-30)

SUNSTAR LUBRICATS
LIMITED

LIQUI Moly Trans

Fluid

C4-SAE 30

TOTAL REFFINAGE
DISTRIBUTION

TOTAL
TRANSMISSION AC

C4-SAE 30

IBP COMPANY LIMITED

IBF TF

C4-SAE 30

MANUAL ELECTRIC CONTROL SYSTEM

SPEED SENSOR

SHIFT SELECTOR

THROTTLE POSITION SENSOR

ECU

SOLENOIDS

DAILY CHECKS:
1. Check the oil level:
At the engine idle RPM the oil level in the sight gauge
should be seen half.
2. Check for any leakages.
3. Check for the codes:
Check for the codes and find the cause for the codes
and correct it.
4. Check for the Check Trans Light:
ON the key such that check Trans light
should glow ON and whenever the ignition is given the check Trans light
should glow OFF. If check Trans light doesnt glow OFF it is that electrical
circuit/transmission is having some problem. So check the problem with
the help of the diagnostic code which is displayed on the shift selector
and correct it.
5. Keep the transmission surroundings clean.

6. Check whether transmission temperature and pressures are in

recommended level or not if not take necessary action in running
condition.

PERIODIC CHECKS:
1. Change the transmission oil at recommended period.
2. Whenever there is a change in the transmission oil change the oil filter
also.
3. Flushing the transmission oil from the cooler lines whenever there is
change in the transmission oil takes place.
4. Check for any defects/looseness in wiring harness at ECU and at
transmission end.
IMPORTANT POINTS:
1. Operating temperature of the transmission should not exceed 135C.
2. While shifting the shift selector from Forward to reverse or from Reverse
to Forward operator should keep the shift selector in neutral until the
vehicle stops and then only operator should shift the selector to either
forward or to reverse.
3. Operator should inform whenever there is a drop in the transmission
pressure which can be known from transmission pressure gauge.
4. Operator should not shift the selector erratically.

SHIFT SELECTOR TROUBLE SHOOTING:

STEPS TO BE FOLLOWED WHILE TROUBLE SHOOTING A SHIFT

SELECTOR:
1. Engine to be turned off
2. Ignition key switch to be turned off - wait for 5 to 8 seconds before
switching of the battery power
3. CEC2 ECU battery power switch present on the rear side of the
cooperators seat to be switched off
4. Wait for 10 minutes for the system to return to normal condition.
5. Turn on the CEC2 ECU battery power switch present behind the cooperator seat.
6. Turn on the ignition key switch and crank the engine.
7. Check the transmission CEC2 system to find if any inhibit condition is
present once the inhibit condition is not present -check for transmission
shifter function.
8. If the service engineer wants to cross check the shifter function in
another equipment follow step 1 to 4 before disconnecting the shifter
from present equipment.
9. Ensure the equipment in which the shifter is going to be checked is not
having any error code
10.Follow step 1 to 4 on the equipment on which the shifter will be checked
before disconnecting the existing shifter on the equipment and after
installation of the shifter to be checked and then follow step 5 to 7
11.Once the checking is over on another equipment follow step 1 to 4
before disconnecting the shifter fitted for testing and re install the
original shifter of the equipment

DOS AND DONTS IN OPERATING THE SHIFT SELECTOR:

1. Hold over ride button to be used only during change in direction of the
equipment.
2. Not to press the HOLD OVER RIDE Button while selecting from D to Lower
ranges.
3. For the forward motion D position to be selected.
4. Equipment speed to be reduced and STOPPED before changing the
direction of motion
5. Shift lever should not be dragged fastly from FWD to REV.
6. Pause to be given in N during changing the direction.
7. Not to hold the shift lever knob always while driving the equipment.

CEC 2 COMPONENTS

SOLENOID BANK

PIN DETAILS IN BLUE HARNESS