Transmicion R1600

CATERPILLAR ELPHINSTONE PTY. LTD.

R1600 LHDR1600 LHDR1600 LHDR1600 LHDR1600 LHDSerSerSerSerService Tvice Tvice Tvice Tvice Training Guidesraining Guidesraining Guidesraining Guidesraining Guides

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POWER TRAINPOWER TRAIN

ContentsContentsContentsContentsContentsIntroduction .................................................................3

Power Train Component Location ...............................4

Torque Converter ........................................................5

Torque Converter (Converter Drive) ............................6

Torque Converter (Direct Drive) ..................................7

Torque Converter Hydraulic System Schematic .........8

Lockup Clutch Valve (Torque Converter Drive) ...........9

Lockup Clutch Valve (Clutch Filling) ..........................10

Lockup Clutch Valve (Direct Drive) ............................11

Torque converter Updrive Transfer Gears .................12

Transmission Oil Flow ...............................................13

Transmission Oil Pump .............................................14

Torque Converter Scavenge Pump ...........................15

Solenoid Valves .........................................................16

Transmission Hydraulic Control Group......................17

Transmission Hydraulic System Operation (Neutral) 18

Transmission Hydraulic System Operation (First -

Speed Forward) ........................................................19

Transmission Pressure Tap Location.........................20

Planetary Transmission .............................................21

Output Transfer Gears ...............................................22

Axle Group ................................................................23

Autoshift Transmission Electronic Control System ....24

Transmission Electronic Control Module ...................25

Input Components .....................................................26

Input Components .....................................................27

Sensor and Switch Inputs .........................................28

Output Components ..................................................29

Diagnostic Operation.................................................30

Find System Faults (Practical Task) ..........................31

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Introduction

The colour codes for hydraulic oil used throughout this presentation are as follows:

Red Red Red Red Red - System or high pressure.Red and White StripesRed and White StripesRed and White StripesRed and White StripesRed and White Stripes - Reduced pressure.OrangeOrangeOrangeOrangeOrange - Torque converter inlet pressure.BrownBrownBrownBrownBrown - Lubrication or cooling oil.Green - Green - Green - Green - Green - Tank or return oil

• Introduction:

• Schematic colourcode:

• Testing &Adjustingprocedures:

• Serviceman’sHandouts:

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71 62 43

148 139 1210 11

(11Power Train Component Location

(1) Front driveshaft, (2) Output transfer gearbox, (3) Transmission, (4) Upper driveshaft,(5) Torque converter updrive transfer gears, (6) Torque converter, (7) Engine,(8) Front differential, (9) Front final drives, (10) Centre bearing, (11) Centre driveshaft,(12) Rear driveshaft, (13) Rear differential, (14) Rear final drives.

• Power TrainComponents:

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1. Torque converter.

2. Torque converter outlet relief valve.

3. Converter lock up clutch control valve.

4. Converter scavenge pump.5. Transmission pump.

Torque Converter

• The torqueconverter providesa fluid coupling intorque converterdrive- Speeds N, 1stforward

• The torqueconverter providesa mechanicalcoupling in directdrive- Speeds 2 to 4forward- Speeds 1 to 4reverse

• The torque goes toconverter drivebetween each shift(during clutchengagement) toprovide smoothshifts

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Torque Converter (Converter Drive)

• Torque converterin torque converterdrive

• Oil flows from thetransmissionhydraulic controlto the impeller

• The impellerdirects the oil intothe blades of theturbine andcauses the turbineto rotate

• The turbine andoutput shaft rotateslower than theengine andimpeller, but withincreased torque

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Torque Converter (Direct Drive)

• Torque converterin direct drive

• The lockup clutchis engaged andlocks the turbineto the impeller

• The housing,impeller, turbineand output shaftrotate as a unit atengine rpm

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Speed Clutch Oil

Converter Inlet Oil

Converter Outlet Oil

Lubrication Oil

Tank Oil

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Torque Converter Hydraulic System Schematic

(1) Transmission hydraulic control valve, (2) Transmission oil filter, (3) Torque converter,(4) Transmission oil pump, (5) Outlet relief valve, (6) Magnetic screen,(7) Oil system reservoir, (8) Transmission oil cooler.

• The outputtransfer gearcaseis the reservoir forthe transmissionoil system

• The transmissionhydraulic controlvalve dividespump flowbetween thetorque converterand transmissionhydraulic systems

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FROMTRANSMISSION

TOLOCKUPCLUTCH

PRESSUREREDUCTION

VALVELOCKUP

SOLENOID

SHUTTLEVALVE

SELECTORPISTON

LOADPISTON

MODULATIONREDUCTION

LOAD PISTONORIFICE

LOCKUP CLUTCH VALVETORQUE CONVERTER DRIVE

Lockup Clutch Valve (Torque Converter Drive)In this illustration and those that follow, the colours used to identify the various pressures in thesystems are as follows:

Red - Red - Red - Red - Red - Supply oil pressureGreen - Green - Green - Green - Green - Drain or tank oilRed and White Stripes - Red and White Stripes - Red and White Stripes - Red and White Stripes - Red and White Stripes - Lockup clutch pressureBrown - Brown - Brown - Brown - Brown - Lubrication or cooling pressureOrange - Orange - Orange - Orange - Orange - Pilot or torque converter pressureYellow - Yellow - Yellow - Yellow - Yellow - Moving components

• Lockup clutch andsolenoid valve intorque converterdrive

• Supply oil from thetransmissionpump is used toprovide lockupclutch oil

• This supplypressure isreduced to providepilot pressure tothe solenoid valve

• When the solenoidis energized,supply pressure isreduced by themodulationreduction valve toprovide lockupclutch pressure

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ExitExit CATERPILLAR ELPHINSTONE PTY. LTD.CLUTCH FILLINGLOCKUP CLUTCH VALVE

FROMTRANSMISSION

TOLOCKUP CLUTCH

PRESSUREREDUCTION

SHUTTLEVALVE

SELECTORPISTON

LOADPISTON

MODULATIONREDUCTION

LOAD PISTONORIFICE

LOCKUPSOLENOID

Lockup Clutch Valve (Clutch Filling)

• Lockup solenoidenergized

• The lockupsolenoid valvedirects pilotpressure to movethe selector pistonand load pistondown

• The load pistonsprings move themodulationreduction valvespool down. Thismovement opensthe supplypassage from thetransmissionpump and permitspressure oil toflow to the lockupclutch

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ExitExit CATERPILLAR ELPHINSTONE PTY. LTD.DIRECT DRIVELOCKUP CLUTCH VALVE

FROMTRANSMISSION

TOLOCKUPCLUTCH

PRESSUREREDUCTION

SHUTTLEVALVE

SELECTORPISTON

LOADPISTON

MODULATIONREDUCTION

LOAD PISTONORIFICE

LOCKUPSOLENOID

Lockup Clutch Valve (Direct Drive)

• Lockup clutch atmaximumpressure

• The modulationreduction valvecauses themaximumpressure setting ofthe clutch to belower then thetransmissionsupply oilpressure

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Torque Converter Updrive Transfer Gears

(1) Drive fromengine flywheel

(2) Torqueconverteroutput shaft

(3) Drive for theimplement,steering andpilot pumps

(4) Drive for thetorqueconverterscavenge andtransmissionpumps

(5) Torqueconverterupdrive output

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1 2 3 4 5 6 7 8 9 10

131211

Transmission Oil Flow

(1) Oil cooler, (2) Torque converter housing,(3) Torque converter,(4) Updrive transfer gearcase, (5) Lubrication line, (6) Oil pump, (7) Pressure filter,(8) Control valve, (9) Transmission, (10) Case, (11) Scavenge pump,(12) Outlet relief valve,(13) Screen magnetic.

• Components

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1. Transmission pump.

2. Transmission oil filter.

4. Transmission oil cooler.

3. Magnetic screen.

Transmission Oil Pump

• Transmission oilpumpcomponents:(1) Transmission

oil pump(2) Transmission

oil filter(3) Magnetic

screen(4) Transmission

oil cooler

• Transmission oilpump is the frontsection of adouble sectiongear type pump

• Transmission oilfilter is locatedabove the updrivetransfer gearcase

• Transmission oilcooler uses enginecoolant to cool oilreturning from thetorque converterto thetransmission

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Torque Converter Scavenge Pump

• Torque converterscavenge pump isthe rear section ofthe double sectiongear type pumpmounted on theupdrive transfergearcase

• Oil leakage withinthe torqueconverter isreturned to thetransmission oilreservoir by thescavenge pump

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Solenoid Valves

• The solenoidvalves are locatedin thetransmissionhydraulic controls

• Two position threeway solenoid valvenormally open

• Two solenoidsenergised:• One speed clutch• One directionalclutch

• Chart showing:• Speed• Solenoidenergised• Clutchesengaged

Speed Solenoids Energised Clutches Engaged1-F 2, 6 2, 62-F 2, 5 2, 53-F 2, 4 2, 44-F 2, 3 2, 3N 3 3

1-R 1, 6 1, 62-R 1, 5 1, 53-R 1, 4 1, 44-R 1, 3 1, 3

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TRANSMISSIONHYDRAULIC CONTROL VALVE

MODULATIONRELIEF VALVE

SECOND AND FOURTHSPEED SELECTOR SPOOL

LOAD PISTON

FIRST AND THIRD SPEEDSELECTOR SPOOL

PRESSUREDIFFERENTIALVALVE

DIRECTIONALSELECTORSPOOL

CONVERTER INLETRATIO VALVE

Transmission Hydraulic Control Group

• Located on top ofthe transmissionplanetary group

• Regulate andcontrol the oilsupply to thetorque converter,transmissionclutches andlubrication circuit

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TRANSMISSION HYDRAULIC SYSTEMNEUTRAL

Transmission Hydraulic System Operation (Neutral)

• Transmissionhydraulic system,transmission inneutral

• ECM energizes theNo.3 solenoid. Oilflow from thesolenoid valvemoves the selectorspool. Oil fromthe selector andpressure controlvalve flowsthrough the orificeto the No.3 speedclutch

• In neutral theforward andreverse solenoidsare not energized.Oil flow to thedirectionalclutches isblocked

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6 1 5 4

TRANSMISSION HYDRAULIC SYSTEMFIRST SPEED FORWARD

Transmission Hydraulic System Operation (First Speed Forward)

• Transmissionhydraulic system,transmission infirst speed forward

• Electronictransmissioncontrol moduleenergizes clutchsolenoids No.2and No.6. Oil fromsolenoid valveNo.2 moves thedirectional clutchselector spool (F).Directional clutchoil flows from theselector spool intothe forwarddirectional clutch

• Oil from solenoidvalve No.6 movesselector spool (G)and sends oilthrough the orificeto clutches No.4and No.6

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Transmission Pressure Tap Location

Always refer to the Service Manual for the correct adjusting procedure and specifications.

• Transmissionpressure taplocation(1) (P1) - Speed

clutch(2) (P2) - Direction

clutch(3) (P3) - Torque

converter inlet(4) (P4) - Plug for

the load piston(LP)

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1 62 53 4

Planetary Transmission

• The transmissionhas six clutchesthat give fourforward and fourreverse speeds

• The transmissionhas two directionalclutches and fourspeed clutches

• One directionalclutch and onespeed clutch mustengage to transmitpower through thetransmission

Transmission Selection Clutches Engaged in TransmissionNeutral 3First Speed Forward 2 and 6Second Speed Forward 2 and 5Third Speed Forward 2 and 4Fourth Speed Forward 2 and 3First Speed Reverse 1 and 6Second Speed Reverse 1 and 5Third Speed Reverse 1 and 4Fourth Speed Reverse 1 and 3

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Output Transfer Gears

(1) Drive gear, (2) Driven gear, (3) Shaft, (4) Yoke assembly front, (5) Yoke assembly rear.

• Output transfergear components:

• Lubrication isprovided by splashfeed from returnoil in the bottom ofthe case

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Axle Group

(1) Differential and bevel gear, (2) Brake discs, (3) Final drive carrier,(4) Final drive planet gears, (5) Axle shaft, (6) Final drive ring gear,(7) Final drive sun gear.

• The differentialsends the sameamount of torqueto each wheel

• The final drivescause the lastspeed reductionand torqueincrease in thedrivetrain

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TRANSMISSIONELECTRONICCONTROLLER

STARTRELAY

BACKUPALARM

TRANSMISSIONCONTROLSOLENOIDS

RIDECONTROLSOLENOID

LOCKUPCLUTCHSOLENOID

CAT DATA LINK

FORWARD REVERSE

1st GEAR 2nd GEAR 3rd GEAR 4th GEAR

STICCONTROLLER

ENGINE SPEEDSENDER

TRANSMISSION SPEED SENSOR

AUTO/MANUALSHIFT SWITCH

RIDE CONTROLSWITCH

REMOTECONTROL

SWITCH

PARKING BRAKEPRESSURE SWITCH

STEERING LOCKSWITCH

OPTION CODECONNECTOR

KEY STARTSWITCH

TRANSMISSIONNEUTRALISER SWITCH

Autoshift Transmission Electronic Control System

• TransmissionElectronic ControlSystem:

- Inputs to thetransmissionelectronic controlare shown on theleft hand side ofthe diagram

- Outputs from thetransmissionelectronic controlare shown on theright hand side ofthe diagram

• The transmissionelectronic controlis the heart of thetransmissionelectrical system

• The controlreceives variousinputs and sends aresponse throughan output

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Transmission Electronic Control Module

• The TransmissionElectronic Controlis connected tothe CaterpillarMonitoring Systemthrough the CatData Link

• Fault informationcan be read on theMonitoring Systempanel or throughthe ElectronicTechnician (ET)

• The transmissioncontrol has twotypes of inputs:- Switch type- Sensor type

• The data linkallows thetransmissioncontrol to receiveand sendinformation to theCaterpillarMonitoring System

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STIC Controller. 4. Steering lock lever.

5. Component location.

Input Components

• There are threeswitches on theSTIC controller:(1) Direction

switch(2) Upshift switch(3) Downshift

switch

• When thetransmission is inthe MANUALmode, thetransmissionshifts to the exactgear and directionselected by theoperator

• When thetransmission is inthe AUTO mode,the transmissionautomaticallyshifts based onengine andtransmissionoutput speeds

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1. Key start switch.

2. Auto/manual transmission switch.

3. Remote control switch.

4. Ride control switch.

Input Components

• The key startswitch sends asignal to thetransmissioncontrol when theswitch is turned tothe STARTposition

• If the shift switchis in NEUTRAL, thecontrol sendspower to the startrelay to start theengine

• The auto/manualswitch selectseither automatic ormanualtransmissionshifting

• In MANUAL mode,the transmissionwill shift to thespeed anddirection selectedby the operator

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1. Engine speed sensor.

3. Park brake pressure switch.4. Park brake pressure switch.

5. Transmission neutraliser switch.

2. Transmission speed sensor.

Sensor and Switch Inputs

• The transmissioncontrol usesengine speed toset automatic shiftpoints

• The control sendsengine speedinformation to theCaterpillarMonitoring Systemover the data link

• The transmissioncontrol usestransmissionspeed to setautomatic shiftpoints and controlride controlactivation

• The transmissioncontrol sendstransmissionspeed informationto the CaterpillarMonitoring Systemover the data link

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1. Transmission control solenoids.2. Converter lock up clutch solenoid. 3. Ride control solenoid.

4. Start relay. 4. Back up alarm.

Output Components

• The transmissioncontrol activatesthe transmissionsolenoid valves todirect pilot oil tothe ends of thecontrol spool - thecontrol spoolshifts to directpressure oil to thetransmissionclutches

• The transmissioncontrol activatesthe torqueconverter lockupclutch whichengages directdrive

• The transmissioncontrol energisesand de-energisesthe ride controlsolenoid based oninputs to thecontrol

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Diagnostic Operation

• The transmissionelectronic controldetects faults thatoccur in mostinput and outputcircuits

• The control storesthe faultinformation forfuture reference

• The service codeconsists of an MID,a CID and an FMI

• The ModuleIdentifier (MID)tells whichelectronic controldiagnosed thefault

• If the CaterpillarMonitoring Systemshows a numberother than 081during diagnosis,the fault is notrelated to thetransmissionsystem

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Find System Faults (Practical Task)

Each trainee will be required to successfully complete the tasks listed below.

1.1.1.1.1. Connect the diagnostic scroll box (service box) or a PC with the ET program to access thediagnostic function of the transmission electronic control.

2.2.2.2.2. The instructor must disconnect the wiring connector from an input or output switch or sensor.The trainee must troubleshoot and then clear the fault.

Always check the Service Manual for the correct specifications and testing and adjusting procedures.

• Explain tasks:

• Service Manual:

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