416F-444F Transmission (Standard Shift) UENR2302

UENR2302-01 November 2012

Specifications Systems Operation Testingand Adjusting Adjusting 416F, 420F, 422F, 428F, 430F, 432F, 434F and 444F Backhoe Loaders Transmission (Standard shift) LWT1-Up LWT1-Up (Machine) LTG1-Up TG1-Up (Machine) (Machine) LKH1-Up KH1-Up (Machine) (Machine) LNH1-Up LNH1-Up (Machine) (Machine) LDY1-Up (Machine) LRH1-Up (Machine) LBH1-Up (Machine)

SAFETY.CAT.COM

i01658146

Important Safety Information Most accidents that t hat involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary necess ary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or or perform any lubrication, maintenance or repair on this product, until you have read and understood understood the operation, operation, lubrication, maintenance and repair information. information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, heeded , bodily injury or death could occur to you or to other persons. The hazards are identi fied by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows: Attention! Attention! Become Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations Operations that that may cause product damage are identi fied by “NOTICE” labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not speci fically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will w ill not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, information, specifications, and illustrations in this publication are on the basis of information that cations, torques, torques, pressures, pressures, was availabl available at the time that the publication was written. The speci fications, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. job. Caterpillar dealers have the most current information available.

When replacemen replacementt parts parts are requir required ed for this product Caterpillar recommends using Caterpilementt parts parts or parts parts with equival equivalent ent lar replac replacemen specifications cations including, but not limited to, physical dimensions, type, strength and material. material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

UENR2302-01

3

3

UENR2302-01 Table of

Table of

Contents

Contents

Specification Section Torque Converter .................................................. 4 Torque Converter .................................................. 6 Transmission (Standard shift) - Two Wheel Drive ............................................... 8 Transmission (Standard shift) - All Wheel Drive .................................................. 13 Transmission (Standard shif t) - All Wheel Drive ... 19 Transmission (Standard shift) - Two Wheel Drive ............................................... 24 Flexible Coupling Drive ............................. ............ 27 Pump Drive ........................................................... 28 Governor Control .................................................. 30 Governor Control .................................................. 31 Transmission Control ............................................ 33 Solenoid Valve (Standard shift) ............................ 35 Solenoid Valve (Standard shift) ............................ 36 Steering Lines ....................................................... 38

Systems Operation Section General Information .............................................. 40 Torque Converter .................................................. 41 Transmission (Two W heel Drive) ................. ......... 43 Transmission (All Wheel Drive) ............................ 58 Transmission Control ............................................ 61 Transmission Hydraulic System ........................... 68

Testing And Adjusting Section Machine Preparat ion for Troubleshooting ............. 71 Machine Preparat ion for Troubleshooting ............. 73 Operational Checks .............................................. 74 Visual Inspection ................................................... 76 Power Train Troubleshooting ................. ............... 78 Pressure Taps ................ ................. .................. .... 82 82 Transmission and Torque Converter – Test ......... 85

Index Section Index

4

4

UENR2302-01 Specification Section

Specification Section

i04699269

Torque Converter SMCS - 3101 S/N - FBN1-UP S/N - FLY1-UP S/N - JWJ1-UP S/N - JXR1-UP S/N - KSF1-UP S/N - LBH1-UP S/N - LDH1-UP S/N - LDY1-UP S/N - LJJ1-UP S/N - LKH1-UP S/N - LNH1-UP S/N - LNR1-UP S/N - LRH1-UP S/N - LTG1-UP S/N - LWT1-UP S/N - MTR1-UP S/N - PXR1-UP S/N - RAK1-UP S/N - RDF1-UP S/N - RGS1-UP S/N - SEJ1-UP S/N - SJW1-UP S/N - SKR1-UP

5

Illustration 1

g02804136

Table 1

Specification Specification for 212-6215 Torque Converter, and 268-1710 Torque Converter Item

Qty

1

-

2

6

Part -

6V-8455 Bolt

Specification description Apply Loctite Loctite C5A copper copper anti-seiz anti-seize e to the the pilot pilot of of the the torque torque conv converter erter tha thatt fits fits in the the engine engine flywheel. Before assembly, degrease the threads in the torque converter housing. Torque to 55 ± 5 N·m (41 ± 4 lb ft).

6

i04708551

Torque Converter SMCS - 3101 S/N - FBN1-UP S/N - FLY1-UP S/N - JXR1-UP S/N - LBH1-UP S/N - LDH1-UP S/N - LJJ1-UP S/N - LNR1-UP S/N - MTR1-UP S/N - PXR1-UP S/N - RAK1-UP S/N - SEJ1-UP S/N - SJW1-UP

Illustration 1

g02813616

Table 1

Specification Specification for 349-0756 Torque Converter, and 361-6047 Torque Converter

7

Item

Qty

1

4

2

-

Part

6V-8455 Bolt

Specification description Before assembly, degrease the threads in the torque converter housing. Torque to 55 ± 5 N·m (41 ± 4 lb ft).

-

Apply Loctite Loctite C5A copper copper anti-seiz anti-seize e to the the pilot pilot of of the the torque torque conv converter erter tha thatt fits fits in the the engine engine flywheel.

8

i04706400

Transmission (Standard Shift) - Two Wheel Drive SMCS - 3060 S/N - KSF1-UP S/N - LRH1-UP S/N - LWT1-UP

Illustration 1 Front view

g02811557

Table 1

Specification Specification for 359-0391 Direct D irect Drive Transmission Gp Item

Qty

Part

Specification description

1

10

334-5131 Plug As

Torque to 40 to 54 N·m (30 to 40 lb ft).

2

2

7T-3249 Screw


3

2

6Y-1341 Spring

Length under test force is 23.8 mm (0.94 inch). Test force is 157 to 177 N (35 to 40 lb).

4

2

6V-5215 Bolt


9

Illustration 2 Top view

g02811558

Table 2 5

1

6V-8378 Nut

Torque to 2.25 ± 0.25 N·m (19.91 ± 2.21 lb i n).

6

1

4W-9972 Temperature Sender As


7

2

6V-7731 Bolt


8

4

9X-6615

Torque to 7.0 to 9.0 N·m (5.0 to 6.3 lb ft). After After fittin fitting g the the bolts, bolts, ensu ensure re that that plastic plastic plug plugs s prov provided ided with with valve alve are are fitted. fitted.

9

1

147-0209 Relief Valve Gp


10

-

305-3423 Solenoid Valve Gp


11

3

8C-5748 Bolt


12

-

-

Torque to 3.8 to 6.8 N·m (2.8 to 5.0 lb ft).

13

1



10

Illustration 3 Rear view

g02811559

Table 3 14

1

293-2147 Breather As


15

-

-

Assemble Assemb le the cover so that the cover is flush with the recess of the lever.

16

1

6V-8097 Bolt


17

1

6Y-1896 Drain Drai n Plug Plug As


18

17

6V-8335 Self-Locking Bolt


11

Table 4 19 4

8C-5748 Bolt

1. Tighten the bolts in a crisscross sequence to 7 N·m (62 lb in). 2. Again, tighten the bolts in the crisscross sequence to 32 N·m (283 lb in).

Thickness of five new friction discs and five new friction discs for the forward clutch and reverse clutch is 19.25 ± 0.65 mm (0.758 ± 0.026 inch). 20

10

6Y-7929 Friction Disc

Thickness of one new friction disc is 2.05 ± 0.08 mm (0.081 ± 0.003 inch). inch).

10

274-4553 Friction Disc

Thickness of one new friction disc is 1.78 to 1.88 mm (0.070 to 0.074 inch).

21 -

-

22 16 336-6851 Piston Spring

The surface must be clean, free from oil and grease. Apply purple Loctite hi-temp Flange sealant to the mating surfaces of front transmission case group and rear transmission case group. Free length after test is 22.20 ± 0.25 0 .25 mm (0.874 ± 0.010 inch).

As requ required, ired, use th the foll followin owing g shims shims in order to obtain an end end play play of 0.03 to 0.08 mm (0.001 to 0.003 inch). All the shims must be located against the bearing cup of the rear transmission case group. The 7T-3034 Spacer must be in contact with the rear transmission case group. 1 1 23 1 1 1 1 1

7T-3034 Spacer

Thickness of one spacer is 1.98 to 2.02 mm (0.078 to 0.080 inch).

6T-9144 Shim

Thickness Thickness of one shim is 0.05 mm (0.002 inch).

6T-9147 Shim


6T-9146 Shim


6T-9145 Shim


6T-9143 Shim


6T-9142 Shim


As requ required, ired, use th the foll followin owing g shims shims in order to obtain an end end play play of 0.03 to 0.08 mm (0.001 to 0.003 inch). All the shims must be located against the bearing cup of the rear transmission case group. The 121-7398 Spacer must be in contact with the rear transmission case group. 1 24 1 1 1 1

121-7398 Spacer

Thickness of the spacer is 2.0 mm (0.08 inch).

121-7399 Shim

Thickness of one shim is 0.051 mm (0.0020 inch).

121-7400 Shim


121-7401 Shim


121-7402 Shim


As requ required, ired, use th the foll followin owing g shims shims in order to obtain an end end play play of 0.03 to 0.08 mm (0.001 to 0.003 inch). All the shims must be located against the bearing cup of the rear transmission case group. The 7T-2646 Spacer must be in contact with the rear transmission case group. 2

7T-2646 Spacer


6T-9166 Shim

Thickness Thickness of one shim is

12

2 2 2 26 1

6T-9165 Shim


6T-9164 Shim


6T-9163 Shim


274-8625 Countershaft Gear

27 1

302-8432 Lip Type Seal

28 1

259-1831 Gear

Apply Loctite Loctite 648 to the the bore bore of the the count counter er shaft shaft gear before before assembl assembly. y.

Lubricate the sealing lip of the lip type seal with the lubricant that is being sealed. Apply Loctite Loctite 648 to the the bore bore of the the gear before before assembl assembly y.

13

i04706509

Transmission (Standard Shift) - All Wheel Drive SMCS - 3060 S/N - FLY1-UP S/N - KSF1-UP S/N - LBH1-UP S/N - LDH1-UP S/N - LRH1-UP S/N - LWT1-UP S/N - MTR1-UP S/N - RAK1-UP S/N - SJW1-UP


g02811696

Table 1

Specification Specification for 359-0393 Direct Drive Transmission Gp, and 359-0395 Direct Drive Transmission Gp Item

Qty

Part

1

9

334-5131 Plug As

Specification description Torque to 40 to 54 N·m (30 to 40 lb ft).

14

2

1

6V-8097 Bolt

3

2

7T-3249 Screw


4

4

121-9875 Bolt


5

2

6V-5215 Bolt


6

2

6Y-1341 Spring

68 to 88 N·m (50 to 65 lb ft).



g02811716

Table 2 7

1

6V-8378 Nut

Torque to 2.25 ± 0.25 N·m (19.91 ± 2.21 lb i n).

8

1



9

2

6V-7731 Bolt


10

4

9X-6615 Bolt


-

15

46 to 60 N·m (34 to 44 lb ft).

12

2



13

-

-


14

1



15

3

8C-5748 Bolt



g02811718

Table 3 16

-

-


17

1



18

1

342-3830 Adapter Adap ter

Apply blue Loctite Locti te 242 to the threads.

19

-

-


20

1

6V-8097 Bolt


21

1

Drai n Plug Plug As 6Y-1896 Drain


22

14



16

Illustration 4 Section H-H

g02811719

Table 4 23 -

-

The surface must be clean, free from oil and grease. Apply purple Loctite hi-temp Flange sealant to the mating surfaces of front transmission case group and rear transmission case group.


10



10




Free length after test is 22.2 mm (0.87 inch).

As requ required, ired, use th the foll followin owing g shims shims in order to obtain an end end play play of 0.03 to 0.08 mm (0.001 to 0.003 inch). All the shims must be located against the bearing cup of the rear transmission case group. The 7T-3034 Spacer must be in contact with the rear transmission case group. 1 1 26 1 1 1

7T-3034 Spacer


6T-9144 Shim


6T-9147 Shim


6T-9146 Shim


6T-9145 Shim


17

1 1

6T-9143 Shim


6T-9142 Shim


As requ required, ired, use th the foll followin owing g shims shims in order to obtain an end end play play of 0.03 to 0.08 mm (0.001 to 0.003 inch). All the shims must be located against the bearing cup of the rear transmission case group. The 121-7398 Spacer must be in contact with the rear transmission case group. 1 27 1 1 1 1 28 1

121-7398 Spacer


121-7399 Shim


121-7400 Shim


121-7401 Shim


121-7402 Shim


122-3650 Plug



31 1

7T-2646 Spacer


6T-9166 Shim


6T-9165 Shim


6T-9164 Shim


6T-9163 Shim


274-8625 Countershaft Gear 259-1831 Gear


Apply Loctite Loctite 648 to the the bore bore of the the gear before before assembl assembly y.

As requ required, ired, use th the foll followin owing g shims shims in order to obtain an end end play play of 0.03 to 0.08 mm (0.001 to 0.003 inch). All the shims must be located against the bearing cup of the rear transmission case group. The 122-1879 Spacer must be in contact with the rear transmission case group. 1 32 1 1 1 1 33 1

122-1879 Spacer

Thickness of the spacer is 1.98 to 2.02 mm (0.078 to 0.080 inch).

104-3288 Shim


121-2059 Shim


121-2060 Shim


121-2061 Shim


178-9566 Piston Spring

Free length is 54.56 mm (2.148 inch).

18

Thickness of eight new friction discs and eight new friction discs for the all wheel drive clutch is 31.04 ± 1.04 mm (1.222 ± 0.041 inch). 34

8



8



19

i04706850

Transmission (Standard Shift) - All Wheel Drive SMCS - 3060 S/N - JWJ1-UP S/N - LDY1-UP S/N - LKH1-UP S/N - LNH1-UP S/N - LNR1-UP S/N - LTG1-UP S/N - PXR1-UP S/N - RDF1-UP S/N - RGS1-UP S/N - SEJ1-UP S/N - SKR1-UP


g02812077

Table 1

Specification Specification for 359-0394 Direct D irect Drive Transmission Gp

20

1

9

334-5131 Plug As


2

1

6V-8097 Bolt


3

2

7T-3249 Screw


4

4

121-9875 Bolt


5

2

6V-5215 Bolt


6

2

6Y-1341 Spring



g02812078

Table 2 7

1

6V-8378 Nut

Torque to 2.25 ± 0.25 N·m (19.91 ± 2.21 lb i n).

8

1



9

2

6V-7731 Bolt


21

10

4

9X-6615 Bolt


11

1



12

-



13

-

-


14

1



15

7

8C-5748 Bolt



g02812079

Table 3 16

-

-


17

1



18

1

342-3830 Adapter Adap ter

Apply blue Loctite Locti te 242 to the threads.

19

-

-

Assemble Assemb le the cover so that the cover is flush with the recess of the lever. Before assembly, apply purple Loctite hi-temp Flange sealant to the threads.

20

1

189-5746 Speed Sensor S ensor Gp

21

1

6V-8097 Bolt


22

1

6Y-1896 Drain Drai n Plug Plug As


23

14



Torque to 25 ± 5 N·m (221 ± 44 lb in).

22

Illustration 4 Section H-H

g02812080

Table 4 Thickness of five new friction discs and five new friction discs for the forward clutch and reverse clutch is 19.40 ± 0.65 mm (0.764 ± 0.026 inch). 24

25

10


Thickness of one new friction disc is 2.05 ± 0.08 0 .08 mm (0.081 ± 0.003 inch).

10



16


Free length after test is 22.2 mm (0.87 inch).


7T-3034 Spacer


1

6T-9144 Shim


26 1

6T-9147 Shim


1

6T-9146 Shim


1

6T-9145 Shim


1

6T-9143 Shim


23

1

6T-9142 Shim


As requ required, ired, use th the foll followin owing g shims shims in order to obtain an end end play play of 0.03 to 0.08 mm (0.001 to 0.003 inch). All the shims must be located against the bearing cup of the rear transmission case group. The 121-7398 Spacer must be in contact with the rear transmission case group.

121-7398 Spacer


27 1

121-7399 Shim


1

121-7400 Shim


1

121-7401 Shim


1

121-7402 Shim


1

As requ required, ired, use th the foll followin owing g shims shims in order to obtain an end end play play of 0.03 to 0.08 mm (0.001 to 0.003 inch). All the shims must be located against the bearing cup of the rear transmission case group. The 7T-2646 Spacer must be in contact with the rear transmission case group.

7T-2646 Spacer


28 2

6T-9166 Shim


2

6T-9165 Shim


2

6T-9164 Shim


2

6T-9163 Shim


1


Apply Loctite Locti te 648 to the bore of the counter shaft gear before assembly.

1

259-1831 Gear

Apply Loctite Locti te 648 to the bore of the gear before assembly. assemb ly.

2

29 30

As requ required, ired, use th the foll followin owing g shims shims in order to obtain an end end play play of 0.03 to 0.08 mm (0.001 to 0.003 inch). All the shims must be located against the bearing cup of the rear transmission case group. The 122-1879 Spacer must be in contact with the rear transmission case group.

122-1879 Spacer

Thickness of the spacer is 1.98 to 2.02 mm (0.078 to 0.080 inch).

31 1

104-3288 Shim


1

121-2059 Shim


1

121-2060 Shim


1

121-2061 Shim


1


Free length is 54.56 mm (2.148 inch).

1

32

Thickness of eight new friction discs and eight new friction discs for the all wheel drive clutch is 31.04 ± 1.04 mm (1.222 ± 0.041 inch). 33

8


Thickness of one new friction disc is 2.05 ± 0.08 0 .08 mm (0.081 ± 0.003 inch).

8



24

i04705329

Transmission (Standard Shift) - Two Wheel Drive SMCS - 3060 S/N - JWJ1-UP S/N - LKH1-UP S/N - LTG1-UP S/N - SKR1-UP

Illustration 1 g02810 g02810216 216 Front view

Table 1

Specification Specification for 359-0392 Direct D irect Drive Transmission Gp Item

Qty

Part

Specification description

1

10

334-5131 Plug As


2

2

7T-3249 Screw


3

2

6Y-1341 Spring


4

6V-5215 Bolt

2


Illustration 2 g02810 g02810217 217 Top view

Table 2 5

1

6V-8378 Nut

Torque to 2.25 ± 0.25 N·m (19.91 ± 2.21 lb i n).

6

1



7

2

6V-7731 Bolt


8

4

9X-6615 Bolt

Torque to 7.0 to 9.0 N·m (5.0 to 6.3 lb ft). After After fittin fitting g the the bolts, bolts, ensu ensure re that that plastic plastic plug plugs s prov provided ided with with valve alve are are fitted. fitted.

25

9

1



10

-

- 305-3423 Solenoid Valve Gp


11

3

8C-5748 Bolt


12

-

-


13

1



Illustration 3 g02810 g02810218 218 Rear view

Table 3 14

1



15

-

-


16

1

S ensor Gp 189-5746 Speed Sensor

Torque to 25 ± 5 N·m (221 ± 44 lb in).

17

1

6V-8097 Bolt


18

1

Drai n Plug Plug As 6Y-1896 Drain


19

17



Illustration 4 g02810 g02810219 219 Section G-G

Table 4 20 4

8C-5748 Bolt

1. Tighten the bolts in a crisscross sequence to 7 N·m (62 lb in). 2. Again, tighten the bolts in the crisscross sequence to 32 N·m (283 lb in).


10



10



22 -

-


The surface must be clean, free from oil and grease. Apply purple Loctite hi-temp Flange sealant to the mating surfaces of front transmission case group and rear transmission case group. Free length after test is 22.20 ± 0.25 0 .25 mm (0.874 ± 0.010 inch).


7T-3034 Spacer


26

1 24 1 1 1 1 1

6T-9144 Shim


6T-9147 Shim


6T-9146 Shim


6T-9145 Shim


6T-9143 Shim


6T-9142 Shim


As requ required, ired, use th the foll followin owing g shims shims in order to obtain an end end play play of 0.03 to 0.08 mm (0.001 to 0.003 inch). All the shims must be located against the bearing cup of the rear transmission case group. The 121-7398 Spacer must be in contact with the rear transmission case group. 1 25 1 1 1 1

121-7398 Spacer


121-7399 Shim


121-7400 Shim


121-7401 Shim


121-7402 Shim



7T-2646 Spacer


6T-9166 Shim


6T-9165 Shim


6T-9164 Shim


6T-9163 Shim



28 1

302-8432 Lip Type Seal

29 1

259-1831 Gear


Lubricate the sealing lip of the lip type seal with the lubricant that is being sealed. Apply Loctite Loctite 648 to the the bore bore of the the gear before before assembl assembly y.

27

i04708492

Flexible Coupling Drive SMCS - 3252-T3; 3252 S/N - -

Illustration 1

g02813518

Table 1

Specification for 111-7907 Flexible Coupling Drive Gp Item

1

2

Qty Qty

-

6

Part -

6V-8455 Bolt

Copyright 1993 - 2014 Caterpillar Inc. All Rights Reserved. Reserved. Private Network For SIS Licensees.

Specification Specification Description Apply Loctite Loctite C5A Copper Copper Anti-Seiz Anti-Seize e to to the the pilot of the the torqu torque e conv converter erter tha thatt fits fits in the the engine engine flywheel. Degrease the threads in the torque converter housing prior to assembly. Torque to 55 ± 5 N·m (41 ± 4 lb ft).

Mon Sep 01 2014 00:29:07 00:29:07 GMT-0700 GMT-0700 (Pacific Standard Time)

28

i04708289

Pump Drive SMCS - 1017; 3108 S/N - FBN1-UP S/N - FLY1-UP S/N - JWJ1-UP S/N - KSF1-UP S/N - LBH1-UP S/N - LDH1-UP S/N - LDY1-UP S/N - LJJ1-UP S/N - LKH1-UP S/N - LNH1-UP S/N - LNR1-UP S/N - LRH1-UP S/N - LTG1-UP S/N - LWT1-UP S/N - MTR1-UP S/N - PXR1-UP S/N - RAK1-UP S/N - RDF1-UP S/N - RGS1-UP S/N - SEJ1-UP S/N - SJW1-UP S/N - SKR1-UP

29

Illustration 1

g02813376

Table 1

Specification Specification for 353-1338 Power Powe r Take-Off Shaft Gp Item

Qty

Part

Specification Description Apply blue blue Loctite Loctite 242 to to the the threads threads..

1

4

8T-9405 Bolt

2

-

-

Torque to 1.7 ± 0.4 N·m (15.0 ± 3.5 lb in). Apply blue Loctite Locti te 242 to the splines.

30

i04708450

Governor Control SMCS - 1265; 1276; 3209 S/N - KSF1-UP S/N - RAK1-UP S/N - RDF1-UP

Illustration 1

g02813481

Table 1

Specification Specification for 341-6720 Governor Control Gp Item

Qty

Part

1

2

3E-8020 Screw

Specification Description Torque to 6 ± 1 N·m (53 ± 9 lb in).

31

i04708429

Governor Control SMCS - 1265; 1276; 3209 S/N - FBN1-UP S/N - FLY1-UP S/N - LBH1-UP S/N - LDH1-UP S/N - LDY1-UP S/N - LJJ1-UP S/N - LKH1-UP S/N - LNH1-UP S/N - LNR1-UP S/N - LRH1-UP S/N - LTG1-UP S/N - LWT1-UP S/N - SEJ1-UP S/N - SJW1-UP

Illustration 1

g02813477

Table 1

Specification Specification for 341-6719 Governor Control Gp

32

1

1

5C-7261 Nut

2

4

095-0641 Bolt

Torque to 15 ± 2 N·m (133 ± 18 lb in). Torque to 1.70 ± 0.25 N·m (15.05 ± 2.21 lb i n).

33

i04708510

Transmission Control SMCS - 3033; 3034-ZS; 3065-ZS; 3065; 3156 S/N - FLY1-UP S/N - JWJ1-UP S/N - KSF1-UP S/N - LBH1-UP S/N - LDH1-UP S/N - LDY1-UP S/N - LKH1-UP S/N - LNH1-UP S/N - LNR1-UP S/N - LRH1-UP S/N - LTG1-UP S/N - LWT1-UP S/N - MTR1-UP S/N - PXR1-UP S/N - RAK1-UP S/N - RDF1-UP S/N - RGS1-UP S/N - SEJ1-UP S/N - SJW1-UP S/N - SKR1-UP

34

Illustration 1

g02813520

Table 1

Specification Specification for 341-6687 Transmission Control Gp and 356-4080 Transmission Control Gp Item Qty Qty

1

1

Part

Specification Specification Description

7X-0620 Hard Washer

Refer to Illustration 1 in order to position the washer as shown to improve the assembly of FNR and multi-function multi-function lever. Before assembly, apply blue Loctite 242 to the threads.

2

2

3

2

4

105-3480 Bolt

Torque to 5.0 ± 0.5 N·m (44.3 ± 4.4 lb in) i n)..

8T-9501 Screw

Torque to 5.5 ± 0.6 N·m (48.7 ± 5.3 lb i n). n).

1

9R-1766 Bottom Cover

Position the knob, so that the NEUTRALIZER switch is 16.2 ± 7.5 degrees from the centerline of the cab.

5

-

-

Apply Loctite Locti te 414 industrial adhesive adhesi ve in the groove of knob bottom.

6

-

-

Refer to Illustration 1 to position the block for 356-4074 Rod As so that the the back surface surface is is perpendicular to the centerline of the machine.

35

i04705511

Solenoid Valve (Standard Shift) SMCS - 3060; 3174-T3 S/N - -

All Wheel Drive and Clutch 1

Illustration 1

g02810457

Table 1

Specification Specification for 305-3423 Solenoid Valve Gp Item

Qty

Part

Specification description Operating voltage voltage is 12 VDC. V DC.

1

1

274-8034 Coil

2

-

-

Installation Installation torque i s 27.2 ± 1.4 N·m (240.7 ± 12.4 lb i n)

3

-

-

Tighten the coil nut nut to 6.1 ± 0.7 N·m (54.0 ± 6.2 lb in) i n)

Resistance at 20° C (68° F) is i s 8.8 ± 0.4 ohm o hms. s.

36

i04705551

Solenoid Valve (Standard Shift) SMCS - 3060; 3174-T3 S/N - FLY1-UP S/N - JWJ1-UP S/N - KSF1-UP S/N - LBH1-UP S/N - LDH1-UP S/N - LDY1-UP S/N - LKH1-UP S/N - LNH1-UP S/N - LNR1-UP S/N - LRH1-UP S/N - LTG1-UP S/N - LWT1-UP S/N - MTR1-UP S/N - PXR1-UP S/N - RAK1-UP S/N - RDF1-UP S/N - RGS1-UP S/N - SEJ1-UP S/N - SJW1-UP S/N - SKR1-UP

Forward and Reverse

37

Illustration 1

g02810496

Table 1

Specification Specification for 324-2578 Solenoid Valve Gp Item

Qty

Part

2

2

274-4560 Self-Locking Nut

3

2

280-7012 Tube As

4

2

336-6824 Plug

5 1

336-6848 Pin

Specification Specification description Torque to 2.5 to 3.5 N·m (1.8 to 2.6 lb ft). Tighten tube assembly into valve body (1) to 25 to 35 N·m (18 to 26 lb ft). Torque to 10 to 20 N·m (8 to 15 lb ft). Diameter of the Pin is 3.18 ± 0.25 mm (0.125 ± 0.010 inch). Protrusion of pin from the surface of valve body (1) is 2.50 ± 0.25 mm (0.098 ± 0.010 inch). inch).

A 6

2

336-4729 Head

-

-

-

Torque to 25 to 35 N·m (18 to 26 lb ft). Operating voltage voltage is 12.0 ± 1.2 VDC. VDC .

38

i04708150

Steering Stee ring Lines SMCS - 4304 S/N - JWJ1-UP S/N - KSF1-UP S/N - LBH1-UP S/N - LDY1-UP S/N - LKH1-UP S/N - LNH1-UP S/N - LNR1-UP S/N - LRH1-UP S/N - LTG1-UP S/N - LWT1-UP S/N - PXR1-UP S/N - RAK1-UP S/N - RDF1-UP S/N - RGS1-UP S/N - SEJ1-UP S/N - SJW1-UP S/N - SKR1-UP

39

Illustration 1

g02813297

Table 1

Specification Specification for 337-9825 Steering Lines Gp Item

Qty

Part

Specification Description

1

1

195-2037 Fitting As

2

6

9X-6772 Cable Cab le Strap

3

1

8T-4182 Bolt

Torque to 35 ± 5 N·m (26 ± 4 lb ft).

4

2

8T-6466 Bolt

Torque to 35 ± 5 N·m (26 ± 4 lb ft).

Torque to 40 ± 4 N·m (30 ± 3 lb ft). Ensure that cable straps do not constrict flow after installation. installatio n.

40 UENR2302-01

System Operation Section

System Operation Section

i03001284

General Information SMCS - 3060 S/N -

FBN1-UP

S/N -

FLY1-UP

S/N -

JWJ1-UP

S/N -

KSF1-UP

S/N -

LBH1-UP

S/N -

LDH1-UP

S/N -

LDY1-UP

S/N -

LJJ1-UP

S/N -

LKH1-UP

S/N -

LNH1-UP

S/N -

LNR1-UP

S/N -

LRH1-UP

S/N -

LTG1-UP

S/N -

LWT1-UP

S/N -

MTR1-UP

S/N -

PXR1-UP

S/N -

RAK1-UP

S/N -

RDF1-UP

S/N -

RGS1-UP

S/N -

SEJ1-UP

S/N -

SJW1-UP

S/N -

SKR1-UP

Power from fro m the diesel die sel engine engi ne is sent s ent from the flywheel flywheel to the torque converter through an arrangement of the flex drive plate. A pilot bore in the the fly flywh wheel eel provides provides alignm alignmen entt for for the the fron frontt end end of the the torqu torque e conv converter erter during during install installation ation.. The torque converter features a free wheel clutch that allows the stator to free wheel during high speed and during low load conditions. A stator stator that that is free free whe wheelin eling g chan changes ges the the conv converter erter into into a flu fluid id couplin coupling g for for bette betterr efficien efficiency cy at the the high speed end. end.

41

i02759361

Torque Converter SMCS - 3101 S/N - FBN1-UP S/N - FLY1-UP S/N - JWJ1-UP S/N - KSF1-UP S/N - LBH1-UP S/N - LDH1-UP S/N - LDY1-UP S/N - LJJ1-UP S/N - LKH1-UP S/N - LNH1-UP S/N - LNR1-UP S/N - LRH1-UP S/N - LTG1-UP S/N - LWT1-UP S/N - MTR1-UP S/N - PXR1-UP S/N - RAK1-UP S/N - RDF1-UP S/N - RGS1-UP S/N - SEJ1-UP S/N - SJW1-UP S/N - SKR1-UP The The torque conv co nverter erter hydraulically connects connects the engine engi ne to the transmissi on. There There is i s no direct di rect mechanical connection between the engine and the transmission. When the the machine works against agai nst a load, the torque torq ue converter can multiply the the torque from the engine, and the converter can send a higher torque to the transmission. The oil for the operation of the torque converter comes from the transmission oil pump. Oil is directed to the transmission circuit and to the torque converter circuit. The torque converter inlet oil pressure is controlled by the relief valve. valve. The relief valve limits limi ts the pressure to the torque converter. Outlet Outlet oil oi l from the converter flows through the the transmission transmiss ion oil oi l cooler

42

Illustration 1 Torque converter

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(1) Housing (2) Flex plate (3) Turbine (4) Impeller (5) Stator (6) Stator clutch

The torque converter consists of the following four main parts: housing (1) , impeller (4) , turbine (3) and stator (5) . The housing is connected to the engine engi ne flywheel flywheel through through flex plate (2) . Impeller (4) and housing (1) are connected. The impeller and a nd the housing housing turn with the engine flywheel at engine speed. Turbine (3) turns the transmission input shaft. Stator (5) is installed on the stationary stator support. Impeller (4) , which turns with housing (1) at engine speed, directs the oil toward the outside of the impeller and against the blades of turbine (3) . The force of the oil that is hitting the turbine blades causes the turbine (3) and the transmission input shaft to rotate. The rotation of the transmission input shaft provides power to the transmission. Oil returns through the stator vanes to the impeller. The stator vanes direct the oil back to the impeller. This causes a torque increase. When the speed of the turbine (3) and the speed of the impeller (4) are equal, the stator clutch (6) permits the stator to turn freely with the rotation of the engine for more efficiency. When turbine torque is greater than impeller torque the stator is locked in place. Torque is multiplied only when the stator is held in place.

43

i03863075

Transmission (Two-Wheel Drive) SMCS - 3060 S/N - JWJ1-UP S/N - KSF1-UP S/N - LKH1-UP S/N - LRH1-UP S/N - LTG1-UP S/N - LWT1-UP S/N - SKR1-UP

44

Transmission (1) Input shaft assembly (2) Forward input gear (3) Reverse idler input gear (4) Forward clutch pack (5) Forward clutch piston (6) Reverse idler shaft (7) Reverse clutch piston (8) Reverse clutch pack (9) Reverse idler driven gear (10) Reverse input gear (11) Caged roller bearings (12) First speed gear (13) First speed and second speed synchronizer assembly (14) Second speed gear (15) Third speed gear (16) Third speed and fourth speed synchronizer assembly (17) Fourth speed gear (18) Output shaft (19) Forward drive gear (20) Countershaft (21) Drive gear (22) Implement pump drive shaft

The transmission has the following features: manual four speed, direct drive helical gear, constant mesh, synchronized arrangement and coupled with wi th hydraulically hydraulically shifted forward fo rward and reverse shuttle shuttle clutches. The The shuttle is a multi-disc clutch arrangement. arrangement. The shuttle shuttle contains two clutch c lutch packs within the input shaft assembly. Each clutch pack contains five plates and five discs. The clutches are hydraulically engaged and released by spring force. Clutch engagement is accomplished through the use of an electrical harness that is connected to the solenoid control valve and the direction selector valve. This hydraulically engages forward clutch (4) or reverse clutch (8) . Input Input shaft assembly assemb ly (1) sends the power from the torque converter turbine to the forward/reverse s shu huttle ttle clutches. The input shaft assembly rotates the same direction as the flywheel. Therefore, the plates also rotate the same direction at the same speed as the input shaft. The input shaft assembly provides four internal oil passages. Two internal oil passages are for lubrication and cooling of the shuttle. The remaining two internal oil passages are for the engagement of the forward clutch pack or the reverse clutch pack. The forward input gear (2) and the reverse input gear (10) are free to rotate on the input shaft assembly (1) when both the forward and the reverse clutch pack are not engaged. The discs rotate with the input gears. Reverse idler shaft (6) and gears (3) and (9) provide reverse rotation to countershaft (20) when the reverse clutch is engaged. Reverse idler driven gear (9) is engaged with reverse input gear (10). The power flows from the reverse idler driven gear (9) to reverse idler input gear (3) when reverse clutch pack (8) is engaged. Countershaft (20) transfers power to the speed range gears on output shaft (18). Drive gear (21) increases roading in fourth gear to approximately 40 km/h (25 mph). The power is transferred from the forward input gear (2) or from the reverse idler input gear (3). The gear that is used depends on the clutch pack that is engaged. Output shaft (18) carries speed range gears (12), (14), (15), and (17) and synchronizer assemblies (13) and (16). All of the speed range gears rotate on caged roller bearings (11).

45

Illustration 2 Synchronizer assembly

g01520897

(23) Cup (24) Shifter fork (25) Sliding collar (26) Cone (27) Split pin (28) Blocker pin

The synchronizer assembly consists of two inner synchronizer cones (26). The cones are mounted to sliding collar (25) by a series of alternating alignment blocker pins (28) and the spring loaded split pins (27). The inner diameter of sliding collar (25) is splined to output shaft (18). The speed range gears have matching splines. Synchronizer cups (23) are splined to the speed range gears and the cups rotate with the speed range gears. When shift fork (24) moves sliding collar (25) to engage a speed gear, the sliding collar comes in contact with the shoulder of the blocker pins (28). The force that is exerted on the blocker pins causes the blocker pin to push the cone against the cup. The assembly of sliding collar (25) and the output shaft (18) are rotating at the same speed as the speed gear. This results in synchronization. If there is a torsional load or mismatch of speeds between the speed range gear and the output shaft, the shoulder of the blocker pin will prevent the sliding collar from engaging. When the speeds are synchronized and there is no torsional load or side load on the blocker pin, the sliding collar will continue to slide as the shifter fork moves. Split pins (27) will collapse and the pin will act as a locking mechanism in order to keep sliding collar (25) engaged with output shaft (18) . The four speed shift lever is on the floor. The operator neutralizes the solenoid control valve of the transmission by depressing the neutralizer neutralizer button on the shift lever and holding the button. This This shifts the speed spee d range gears. g ears. Activating A ctivating the neutralizer button releases a direction clutch and the button places the transmission into NEUTRAL position. Now, the operator can select any speed range gear, even when the vehicle is moving. Once the shift is complete, the neutralizer button must be released. The speed shift is completed and the direction clutch is engaged again. Power is sent from the output shaft to the rear axle. Only one synchronizer assembly can be engaged at a time.

Power Flows (First Speed Forward Or Second Speed Forward)

46

Illustration 3 Power flow in first speed forward (1) Input shaft assembly (2) Forward input gear (3) Reverse idler input gear (4) Forward clutch pack (5) Forward clutch piston (6) Reverse idler shaft (7) Reverse clutch piston (8) Reverse clutch pack (9) Reverse idler driven gear (10) Reverse input gear (11) Caged roller bearings (12) First speed gear (13) First speed and second speed synchronizer assembly (14) Second speed gear (15) Third speed gear (16) Third speed and fourth speed synchronizer assembly (17) Fourth speed gear (18) Output shaft (19) Forward drive gear (20) Countershaft (21) Drive gear

g01224674

47

Illustration 4 Power flow in second speed forward (1) Input shaft assembly (2) Forward input gear (3) Reverse idler input gear (4) Forward clutch pack (5) Forward clutch piston (6) Reverse idler shaft (7) Reverse clutch piston (8) Reverse clutch pack (9) Reverse idler driven gear (10) Reverse input gear (11) Caged roller bearings (12) First speed gear (13) First speed and second speed synchronizer assembly (14) Second speed gear (15) Third speed gear (16) Third speed and fourth speed synchronizer assembly (17) Fourth speed gear (18) Output shaft (19) Forward drive gear (20) Countershaft

g01224910

48

(22) Implement pump drive shaft


g01520898


The The torque conv co nverter erter turbine dri ves input shaft assembly (1). The operator operato r moves the directio di rection n control lever that is mounted on the steering wheel column to the forward position. This engages the forward clutch. The oil pressure is sent through input shaft assembly (1) to pressurized forward clutch piston (5). Forward clutch pack (4) engages and the clutch pack sends power to the forward input gear (2) . Forward input gear (2) transmits the power to drive gear (19), which turns countershaft (20), which is constantly engaged with the speed range gears. The neutralizer button that is located on the shift lever must be activated in order to neutralize the solenoid control valve of the transmission. This engages first speed gear (12) or second speed gear (14) with output shaft (18). Activating the neutralizer button releases a direction clutch and the button places the transmission into NEUTRAL. The shift lever can now be moved into first gear or second gear. Shifter fork (24) slides synchronizer collar (25) to the right so first speed gear (12) engages with output shaft (18). Also, the shifter fork (24) can slide the synchronized collar (25) to the left so second speed gear (14) engages with output shaft (18) . If there is no torsional load or mismatch of speeds between the speed gear and the output shaft, synchronizer assembly (13) will engage the speed gear with the output shaft. Once the shift is complete the neutralizer button must be released. The speed shift is completed and the direction clutch is engaged again. Power is sent from the output shaft to the rear axle.

Power Flows (Third Speed Forward Or Fourth Speed Forward)

49

Illustration 6 Power flow in third speed forward (1) Input shaft assembly (2) Forward input gear (3) Reverse idler input gear (4) Forward clutch pack (5) Forward clutch piston (6) Reverse idler shaft (7) Reverse clutch piston (8) Reverse clutch pack (9) Reverse idler driven gear (10) Reverse input gear (11) Caged roller bearings (12) First speed gear (13) First speed and second speed synchronizer assembly (14) Second speed gear (15) Third speed gear (16) Third speed and fourth speed synchronizer assembly (17) Fourth speed gear (18) Output shaft (19) Forward drive gear (20) Countershaft (21) Drive gear

g01224742

50

Illustration 7 Power flow in fourth speed forward (1) Input shaft assembly (2) Forward input gear (3) Reverse idler input gear (4) Forward clutch pack (5) Forward clutch piston (6) Reverse idler shaft (7) Reverse clutch piston (8) Reverse clutch pack (9) Reverse idler driven gear (10) Reverse input gear (11) Caged roller bearings (12) First speed gear (13) First speed and second speed synchronizer assembly (14) Second speed gear (15) Third speed gear (16) Third speed and fourth speed synchronizer assembly (17) Fourth speed gear (18) Output shaft (19) Forward drive gear (20) Countershaft

g01520927

51



g01520924


The The torque conv co nverter erter turbine dri ves input shaft assembly (1). The operator operato r moves the directio di rection n control lever that is mounted on the steering wheel column to the forward position. This engages the forward clutch. The oil pressure is sent through input shaft assembly (1) to pressurized forward clutch piston (4). Forward clutch pack (4) engages and the clutch pack sends power to forward input gear (2) . Forward input gear (2) transmits the power to drive gear (21) and (19), which turns countershaft (20), which is constantly engaged with the speed range gears. The neutralizer button that is located on the shift lever must be activated in order to neutralize the solenoid control valve of the transmission. This engages third speed gear (15) or fourth speed gear (17) with output shaft (18). Activating the neutralizer button releases a direction clutch and the button places the transmission into NEUTRAL. The shift lever can now be moved into third gear or fourth gear. Shifter fork (24) slides synchronizer collar (25) to the right so third speed gear (15) engages with output shaft (18). Also, the shifter fork (24) can slide the synchronized collar (25) to the left so fourth speed gear (17) engages with output shaft (18) .

Power Flows (First Speed Reverse Or Second Speed Reverse)

52

Illustration 9 Power flow in first speed reverse (1) Input shaft assembly (2) Forward input gear (3) Reverse idler input gear (4) Forward clutch pack (5) Forward clutch piston (6) Reverse idler shaft (7) Reverse clutch piston (8) Reverse clutch pack (9) Reverse idler driven gear (10) Reverse input gear (11) Caged roller bearings (12) First speed gear (13) First speed and second speed synchronizer assembly (14) Second speed gear (15) Third speed gear (16) Third speed and fourth speed synchronizer assembly (17) Fourth speed gear (18) Output shaft (19) Forward drive gear (20) Countershaft (21) Drive gear

g01224758

53

Illustration 10 Power flow in second speed reverse (1) Input shaft assembly (2) Forward input gear (3) Reverse idler input gear (4) Forward clutch pack (5) Forward clutch piston (6) Reverse idler shaft (7) Reverse clutch piston (8) Reverse clutch pack (9) Reverse idler driven gear (10) Reverse input gear (11) Caged roller bearings (12) First speed gear (13) First speed and second speed synchronizer assembly (14) Second speed gear (15) Third speed gear (16) Third speed and fourth speed synchronizer assembly (17) Fourth speed gear (18) Output shaft (19) Forward drive gear (20) Countershaft

g01225227

54



g01520925


The The torque conv co nverter erter turbine dri ves input shaft assembly (1). The operator operato r moves the directio di rection n control lever that is mounted on the steering wheel column to the reverse position. This engages the reverse clutch. The oil pressure is sent through input shaft assembly (1) to pressurized reverse clutch piston (7). The reverse clutch pack (8) engages and the clutch pack sends power to the reverse input gear. Reverse input gear (10) transmits the power to reverse idler driven gear (9), which turns reverse idler shaft (6) and reverse idler input gear (3). Reverse idler input gear (3) transmits the power to drive gear (21) and forward drive gear (19), which turns countershaft (20), which is constantly engaged with the speed range gears. The countershaft will rotate in the reverse direction. The The countershaft is i n constant mesh with speed range gears that are mounted on output shaft (18). The The neutralizer button that that is is located on the shift lever must be activated in order to neutralize the solenoid control valve of the transmission. This engages first speed gear (12) or second speed gear (14) with output shaft (18). Activating the neutralizer button releases a direction clutch and the button places the transmission into NEUTRAL. The shift lever can now be moved into first gear or second gear. Shifter fork (24) slides synchronizer collar (25) to the right so first speed gear (12) engages with output shaft (18). Also, the shifter fork (24) can slide the synchronized collar to the left so second speed gear (14) engages with output shaft (18) . If there is no torsional load or mismatch of speeds between the speed gear and the output shaft, synchronizer assembly (13) will engage the speed gear with the output shaft. Once the shift is complete the neutralizer button must be released. The speed shift is completed and the direction clutch is engaged again. Power is sent from the output shaft to the rear axle.

Power Flows (Third Speed Reverse Or Fourth Speed Reverse)

55

Illustration 12 Power flow in third speed reverse

g01224964

56

Illustration 13 Power flow in fourth speed reverse (1) Input shaft assembly (2) Forward input gear (3) Reverse idler input gear (4) Forward clutch pack (5) Forward clutch piston (6) Reverse idler shaft (7) Reverse clutch piston (8) Reverse clutch pack (9) Reverse idler driven gear (10) Reverse input gear (11) Caged roller bearings (12) First speed gear (13) First speed and second speed synchronizer assembly (14) Second speed gear (15) Third speed gear (16) Third speed and fourth speed synchronizer assembly (17) Fourth speed gear (18) Output shaft (19) Forward drive gear (20) Countershaft (21) Drive gear

g01520929

57


g01520926


The The torque conv co nverter erter turbine dri ves input shaft assembly (1). The operator operato r moves the directio di rection n control lever that is mounted on the steering wheel column to the reverse position. This engages the reverse clutch. The oil pressure is sent through input shaft assembly (1) to pressurized reverse clutch piston (7). The reverse clutch pack (8) engages and the clutch pack sends power to the reverse input gear (10) . Reverse input gear (10) transmits the power to reverse idler driven gear (9), which turns reverse idler shaft (6) and reverse idler input gear (3). Reverse idler input gear (3) transmits the power to drive gears (21) and (19), which turns countershaft (20), which is constantly engaged with the speed range gears. The countershaft will rotate in the reverse direction. The The countershaft is i n constant mesh with speed range gears that are mounted on output shaft (18). The The neutralizer button that that is is located on the shift lever must be activated in order to neutralize the solenoid control valve of the transmission. This engages third speed gear (15) or fourth speed gear (17) with output shaft (18). Activating the neutralizer button releases a direction clutch and the button places the transmission into NEUTRAL. The shift lever can now be moved into first gear or second gear. Shifter fork (24) slides synchronizer collar (25) to the right so third speed gear (14) engages with output shaft (18). Also, shifter fork (24) can slide the synchronized collar to the left so fourth speed gear (17) engages with output shaft (18) . If there is no torsional load or mismatch of speeds between the speed gear and the output shaft, synchronizer assembly (16) will engage the speed gear with the output shaft. Once the shift is complete the neutralizer button must be released. The speed shift is completed and the direction clutch is engaged again. Power is sent from the output shaft to the rear axle.

58

i04637011

Transmission (All-Wheel Drive) SMCS - 3060 S/N - FLY1-UP S/N - JWJ1-UP S/N - KSF1-UP S/N - LBH1-UP S/N - LDH1-UP S/N - LDY1-UP S/N - LJJ1-UP S/N - LKH1-UP S/N - LNH1-UP S/N - LNR1-UP S/N - LRH1-UP S/N - LTG1-UP S/N - LWT1-UP S/N - MTR1-UP S/N - PXR1-UP S/N - RAK1-UP S/N - RDF1-UP S/N - RGS1-UP S/N - SEJ1-UP S/N - SJW1-UP S/N - SKR1-UP

Power Flow

59

Illustration 1 This illustration is an example of the power flow for the all wheel drive. (1) Input shaft assembly (2) Forward input gear (3) Reverse idler input gear (4) Forward clutch pack (5) Forward clutch piston (6) Reverse idler shaft (7) Reverse clutch piston (8) Reverse clutch pack (9) Reverse idler driven gear (10) Reverse input gear (11) Countershaft (12) Input gear for front wheel drive (13) Caged roller bearing (14) First speed gear (15) Gear for the front wheel drive (16) Clutch pack for front wheel drive (17) Clutch piston for front wheel drive (18) Output shaft for front wheel drive (19) First speed and second speed synchronizer assembly (20) Second speed gear (21) Third speed gear

g01225427

60

(23) Fourth speed gear (24) Output shaft (25) Forward drive gear (26) Drive gear (27) Implement pump drive shaft

Illustration 2 (28) All wheel drive switch

g02781881

The output shaft for front wheel drive (18) may be engaged at any time by activating all wheel drive switch (28) that is located on the left side of the front dash panel. The switch may be activated when the vehicle is stopped or while the vehicle is moving. All wheel drive attachments include the following parts: gear for front wheel drive (15), clutch pack for front wheel drive (16) and output shaft for front wheel drive (18). The output shaft for front wheel drive (18) connects the transmission with the steerable front drive axle. When the operator activates all wheel drive switch (28) on the front dash panel, the all wheel drive solenoid is energized. A passage opens in i n order to allow a llow oil under pressure pres sure to flow to the output shaft for front wheel drive (18 ). The oil flows through the output output shaft for front wheel drive (18) in order to engage the clutch pack for front wheel drive (16). The input gear for front wheel drive (12) transmits power to the gear for front wheel drive (15). Power from the gear for front wheel drive (15) is then transmitted through the clutch pack for front wheel drive (16) (16 ) to the output shaft for front wheel drive (18). The output shaft of the front wheel wheel drive dri ve is connected c onnected to the drive dri ve shaft of the front axle.

61

i04637129

Transmission Control SMCS - 3030; 3060; 3065 S/N - FBN1-UP S/N - FLY1-UP S/N - JWJ1-UP S/N - KSF1-UP S/N - LBH1-UP S/N - LDH1-UP S/N - LDY1-UP S/N - LJJ1-UP S/N - LKH1-UP S/N - LNH1-UP S/N - LNR1-UP S/N - LRH1-UP S/N - LTG1-UP S/N - LWT1-UP S/N - MTR1-UP S/N - PXR1-UP S/N - RAK1-UP S/N - RDF1-UP S/N - RGS1-UP S/N - SEJ1-UP S/N - SJW1-UP S/N - SKR1-UP The solenoid control valve for the transmission is installed on top of the transmission housing. The solenoid control valve for the transmission controls the FORWARD, REVERSE, and NEUTRAL functions of the transmission. The solenoid control valve directs the pressurized oil to either the forward clutch pack or to the reverse clutch pack. In the NEUTRAL position, clutch pressure is dumped back to the transmission case. The reverse solenoid of the solenoid control valve for the transmission is electrically connected with the backup alarm switch. The backup alarm switch activates the backup alarm.

62

Illustration 1 (1) Transmission neutral lock (If equipped)

g02781937

(2) Direction control lever (3) Neutralizer controls (If equipped)

The neutralizer switch is located on either the left side of the dash or the loader control lever. The neutral lock switch on the left side of the dash disables all transmission solenoids. The neutralizer switch that is located on the loader control lever disengages the direction control solenoids. If the vehicle is turned off, with the direction control levers in the FORWARD or REVERSE position, the vehicle will not restart. The direction control lever is to be returned to the NEUTRAL position in order to start machine. The solenoids that are located in the solenoid control valve are electronically actuated. The solenoids are actuated by the direction control lever that is o on n the the steering stee ring wheel column. When the solenoid control valve is de-energized, the centering springs center the spool, which blocks the oil flow from the transmission pump. The oil pressure in the direction clutch decreases and the direction clutch disengages when oil flow to the transmission is blocked. When the transmission solenoid is energized, the oil passages to the transmission are opened. The energized solenoid permits the filling of one of the direction clutches. The energized solenoids also allow the pressure to build up in the transmission.

All Wheel Drive (If equipped) The all wheel drive attachment will improve mobility and overall performance of the loader in conditions of poor traction.

63

Illustration 2 (1) All wheel drive switch (if equipped)

g02782018

The front drive axle may be engaged at any time by activating the all wheel drive switch on the left side of the front console. This switch may be activated when the vehicle is stopped or while the vehicle is moving. The following components are required with the all wheel drive attachment: all wheel drive switch, all wheel drive solenoid valve, transmission for the all wheel drive, clutch pack for the all wheel drive that is i s on the output shaft for the all wheel drive, a steerable s teerable front drive axle and front drive dri ve shaft with a guard. The front drive shaft connects the output shaft shaft for the all wheel drive dri ve with the steerable front drive axle.

Transmission Operation

Illustration 3 The transmission hydraulic system in NEUTRAL (1) Oil filter with bypass (2) Clutch pack for the all wheel drive (If equipped)

g01298487

64

(4) All wheel drive solenoid (If equipped) (5) System relief valve (6) Transmission solenoid valve (7) Reverse clutch pack (8) Pressure tap for reverse clutch (9) Pressure tap for forward clutch (10) Forward clutch pack (11) Pressure tap for torque converter inlet (12) Inlet relief valve for torque converter (13) Torque converter (14) Temperature sensor for torque converter outlet (15) Oil Cooler (16) Pressure tap for lubrication and cooling (17) Transmission lubrication system (18) Oil reservoir (19) Suction screen (20) Oil pump (21) Pressure tap for pump (22) Pressure tap for regulated pressure (23) Modulating relief valve

When the engine is running, oil pump (20) pulls oil from reservoir (18) through suction screen (19) to the pump. The oil pump sends the oil through filter (1) and to the control solenoid valve for the transmission (6) . With the direction control lever in the NEUTRAL position, oil flow is blocked by the solenoid control valve. This function will not allow either of the forward clutch pack or the reverse clutch pack can be pressurized. The passages for the clutch oil are open to the drain. The open passages allow oil that is not needed by the transmission circuit to flow through the system relief valve to the torque converter. Torque converter inlet relief valve (12) controls maximum pressure to the torque converter in order to prevent damage during cold starts. Torque converter pressure is maintained in the torque converter by the restrictions that are created by the oil cooler and the oil lines that are leaving the torque converter.

Illustration 4 All whe wheel el driv driv

g02782118 itch (if (if e ipped ipped))

65

With the all wheel drive switch in the OFF position, oil is blocked by the all wheel drive solenoid valve (4). The oil from the clutch pack for the all wheel drive is then connected to the drain. When the all wheel drive switch is in the ON position, the all wheel drive solenoid is energized. When the all wheel drive solenoid is energized, pressurized oil is directed to the clutch pack for the all wheel drive (2) . With the all wheel drive switch in the ALL WHEEL DRIVE BRAKING position, oil flows to the clutch pack for all wheel drive (2). The oil is then blocked by the all wheel drive solenoid valve until both brake pedals are engaged. When both brake pedals are engaged, the all wheel drive solenoid will energize. With an energized all wheel drive solenoid, a passage will open in order to provide an oil passage to the clutch pack (5) .

Run The Engine (Forward)

Illustration 5 The transmission hydraulic system in FORWARD (1) Oil filter with bypass (2) Clutch pack for the all wheel drive (If equipped) (3) Pressure tap on the clutch pack for all wheel drive (If equipped) (4) All wheel drive solenoid (If equipped) (5) System relief valve (6) Transmission solenoid valve (7) Reverse clutch pack (8) Pressure tap for reverse clutch (9) Pressure tap for forward clutch (10) Forward clutch pack (11) Pressure tap for torque converter inlet (12) Inlet relief valve for torque converter (13) Torque converter (14) Temperature sensor for torque converter outlet (15) Oil Cooler (16) Pressure tap for lubrication and cooling (17) Transmission lubrication system (18) Oil reservoir

g01298581

66

(19) Suction screen (20) Oil pump (21) Pressure tap for pump (22) Pressure tap for regulated pressure (23) Modulating relief valve

When the direction control lever on the steering wheel column is moved to the FORWARD position, the forward solenoid of the solenoid valve (6) is electrically activated. The electrical activation of the forward solenoid overrides the centering spring. The spool will then move. Pressurized oil will be able to flow to the forward clutch pack (10) . An orifice within within the the contro controll solen solenoid oid valv valve e establish establishes es a constan constantt flow flow and and pressu pressure re of oil oil to to the the forw forward ard clutch clutch pack. This This orifice orifice allow allows s oil that is not needed by the transmission circuit to flow to the torque converter. The FORWARD position directs oil to the forward clutch pack. The reverse clutch oil passage is open to the drain. Oil fills the forward clutch pack. The pressurized oil will engage the forward clutch pack. When the the forward clutch pack obtai ns maximum system pressure, the relief relie f valve valve (5) opens. o pens. The relief valve helps maintain maintai n maximum system pressure to the forward clutch pack. When relief valve (5) is closed, a bypass orifice within the relief valve still permits the flow of oil to the torque converter at low idle for lubrication and cooling purposes.

Run The Engine (Reverse)

Illustration 6 The transmission hydraulic system in REVERSE (1) Oil filter with bypass (2) Clutch pack for the all wheel drive (If equipped) (3) Pressure tap on the clutch pack for all wheel drive (If equipped) (4) All wheel drive solenoid (If equipped) (5) System relief valve (6) Transmission solenoid valve (7) Reverse clutch pack (8) Pressure tap for reverse clutch (9) Pressure tap for forward clutch (10) Forward clutch pack

g01298590

67

(11) Pressure tap for torque converter inlet (12) Inlet relief valve for torque converter (13) Torque converter (14) Temperature sensor for torque converter outlet (15) Oil Cooler (16) Pressure tap for lubrication and cooling (17) Transmission lubrication system (18) Oil reservoir (19) Suction screen (20) Oil pump (21) Pressure tap for pump (22) Pressure tap for regulated pressure (23) Modulating relief valve

When the direction control lever on the steering wheel column is moved to the REVERSE position, the reverse solenoid of the solenoid valve (6) is electrically activated. The electrical activation of the reverse solenoid overrides the centering spring. The spool will then move. Pressurized oil will be able to flow to the reverse clutch pack (7) . An orifice within within the the contro controll solen solenoid oid valv valve e establish establishes es a constan constantt flow flow and and pressu pressure re of oil oil to to the the rev reverse erse clutch clutch pack. This This orifice orifice allow allows s oil that is not needed by the transmission circuit to flow to the torque converter. The REVERSE position directs oil to the reverse clutch pack. The forward clutch oil passage is open to the drain. Oil fills the reverse clutch pack. The pressurized oil will engage the reverse clutch pack. When the the reverse clutch c lutch pack obtains obtai ns maximum system pressure, the relief relie f valve valve (5) opens. o pens. The relief valve helps maintain maintai n maximum system pressure to the reverse clutch pack. When relief valve (5) is closed, a bypass orifice within the relief valve still permits the flow of oil to the torque converter at low idle for lubrication and cooling purposes.

68

i04637410

Transmission Hydraulic System SMCS - 3060 S/N - FBN1-UP S/N - FLY1-UP S/N - JWJ1-UP S/N - KSF1-UP S/N - LBH1-UP S/N - LDH1-UP S/N - LDY1-UP S/N - LJJ1-UP S/N - LKH1-UP S/N - LNH1-UP S/N - LNR1-UP S/N - LRH1-UP S/N - LTG1-UP S/N - LWT1-UP S/N - MTR1-UP S/N - PXR1-UP S/N - RAK1-UP S/N - RDF1-UP S/N - RGS1-UP S/N - SEJ1-UP S/N - SJW1-UP S/N - SKR1-UP

Torque Converter, Transmission Pump, Screen and Filter A crescen crescentt pum pump p prov provides ides the the oil for for the the operation operation and and the the cooling cooling of the the trans transmission mission and torque torque conv converter. erter. The The pump pump also also delivers delivers oil for lubrication of the transmission and torque converter. The pump is located at the transmission input shaft. The torque converter stator support is assembled with the pump. This assembly is then bolted to the transmission case. The pump is driven by the torque converter impeller housing.

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The oil reservoir for the transmission and for the torque converter is on the bottom of the transmission case. The oil flows from the reservoir to the screen. The oil then flows through a transmission case passage to the suction side of the positive displacement pump. The oil from the pump flows to the filter and the oil from the pump then flows to the transmission hydraulic controls. A restriction in the oil filter or high viscosity oil will open a relief valve. The flow of oil will travel back to the sump of the transmission.

Illustration 1

g01452426

If the pressure differential of the inlet oil pressure to the oil filter (1) is 250 ± 30 kPa (36 ± 4 psi) higher than the outlet oil pressure, the oil filter bypass valve will open. When the oil does not flow through the oil filter element, unfiltered oil could cause damage to other components in the transmission oil system. Correct maintenance must be used in order to make sure that the element does not become plugged. Maintaining the element can help prevent stop of clean oil flow to the transmission oil system. The filter is mounted to the left side of the transmission case. The screen is mounted inside the transmission case. The screen can be removed on the right side of the case.

Power Train Oil Cooler

Illustration 2

g02783117

The transmission oil cooler is mounted on the front of the radiator. High temperature oil from the transmission system flows from the torque converter outlet to the transmission oil cooler. As oil is flowing through the core assembly, air is flowing around the core assembly. In this way, heat is removed from the oil. After After the the oil flow flows s thr throug ough h the the cores cores of the the tran transmission smission oil cooler cooler,, the the oil flow flows s thr throu ough gh the the outl outlet et passage passage of the the core assembly assembly.. The The oil now has a lower temperature. The cooler oil returns to the transmission in order to provide lubrication and cooling.

Transmission Lubrication System

70

Illustration 3

g00757665

The following components are lubricated by pressure in the transmission: forward shuttles, reverse shuttles, discs, plates and bearings. The oil will pass through the oil cooler in order to be cooled. The oil will flow through an internal passage on the right side of the transmission case to the right end of the input shaft. The cooled oil flows through the oil passages in the input shaft assembly. The cooled oil provides lubrication lubrication for the bearings, plates, and discs. Splash lubrication keeps the other gears and bearings oiled. The movement of the gears in the oil reservoir causes oil to be thrown on all components.

71 UENR2302-01

Testing and Adjusting Section

Testing and Adjusting Section

i02438879

Machine Preparation Preparation for for Troubleshooting SMCS - 3060-035 S/N - JWJ1-UP S/N - KSF1-UP S/N - LBH1-UP S/N - LDH1-UP S/N - LDY1-UP S/N - LJJ1-UP S/N - LKH1-UP S/N - LNH1-UP S/N - LNR1-UP S/N - LRH1-UP S/N - LTG1-UP S/N - LWT1-UP S/N - MTR1-UP S/N - PXR1-UP S/N - RAK1-UP S/N - RDF1-UP S/N - RGS1-UP S/N - SEJ1-UP S/N - SJW1-UP S/N - SKR1-UP Make reference to the following warning and pressure tap locations for all checks and tests of the transmission hydraulic system. If the problem area is not known, you should do the tests in the order that is given. If the problem area is not known for all tests, the oil must be at normal temperature of operation.

Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the procedure that follows before the test is done.

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1. Move the the machine to a smooth horizontal location. Move away from from working machines and personnel. pe rsonnel. 2. Put the the transmission transmissi on forward/reverse shuttle shuttle control in the NEUTRAL NEUTRAL position. posi tion. 3. Activate Acti vate the the neutral neutral lockout switch. Stop the engine. 4. Permit Permi t only one operator operato r on the machine. You You should should keep all personnel away from the machine or you should should keep all personnel in the view of the operator. 5. Activate Acti vate the parking parki ng brakes. brakes . 6. Lower the buckets (loader and backhoe) to the ground. ground. Lower the the stabilizers stabi lizers to the ground. ground. 7. Make sure that all hydraulic hydraulic pressure is re released leased before be fore any component is adjusted in any way. Troubleshooting can be difficult. A list of possible problems and corrections is on the pages that follow. This list of problems and corrections will only give an indication of the type of problem and the repairs that are needed. Normally, more repair work or other repair work is needed beyond the recommendations on the list. This list cannot give all possible problems and corrections. The serviceman must find the problem and the source of the problem. The serviceman must then make the necessary repairs. You should make a vis visual ual check first. C heck the operati on of the machine and then check with instrum i nstruments. ents.

73

i05099932

Machine Preparation Preparation for for Troubleshooting SMCS - 3060-035 Make reference to the following warning and pressure tap locations for all checks and tests of the transmission hydraulic system. If the problem area is not known, perform the tests in the order that is given. If the problem area is not known for all tests, the oil must be at normal temperature of operation.

Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the procedure that follows before the test is done. 1. Move the the machine to a smooth horizontal location. Move away from from working machines and personnel. pe rsonnel. 2. Put the the transmission transmissi on forward/reverse shuttle shuttle control in the NEUTRAL NEUTRAL position. posi tion. 3. Activate Acti vate the the neutral neutral lockout switch. Stop the engine. 4. Permit Permi t only one operator on the machine. Keep all personnel pers onnel away from the machine or in the the view of the operator. 5. Activate Acti vate the parking parki ng brakes. brakes . 6. Lower the buckets (loader and backhoe) to the ground. ground. Lower the the stabilizers stabi lizers to the ground. ground. 7. Make sure that all hydraulic hydraulic pressure is re released leased before be fore any component is adjusted in any way. Troubleshooting can be difficult. A list of possible problems and corrections is on the pages that follow. This list of problems and corrections will only give an indication of the type of problem and the repairs that are needed. Normally, more repair work or other repair work is needed beyond the recommendations on the list. This list cannot give all possible problems and corrections. The serviceman must find the problem and the source of the problem. The serviceman must then make the necessary repairs. Make a visual check first. Check the operation of the machine and then check with instruments.

74

i02438891

Operational Checks SMCS - 3060-535 S/N - FBN1-UP S/N - FLY1-UP S/N - JWJ1-UP S/N - KSF1-UP S/N - LBH1-UP S/N - LDH1-UP S/N - LDY1-UP S/N - LJJ1-UP S/N - LKH1-UP S/N - LNH1-UP S/N - LNR1-UP S/N - LRH1-UP S/N - LTG1-UP S/N - LWT1-UP S/N - MTR1-UP S/N - PXR1-UP S/N - RAK1-UP S/N - RDF1-UP S/N - RGS1-UP S/N - SEJ1-UP S/N - SJW1-UP S/N - SKR1-UP


75

1. Start the engine. 2. Lower the stabilizers stabili zers and lift lift the rear wheels wheels 150 mm (6 inch) off the the ground. 3. Use the bucket hydraulic hydraulic control co ntrol to lower the bucket to the ground ground and use the bucket to raise rai se the front wheels wheels 150 15 0 mm (6 inch i nch)) off the ground. 4. The The engine speed needs to be at low idle. 5. Operate the machine in each direction directio n and and in all speeds while the engine is running running and the the brakes are engaged. engaged . Make a note of the noises that are not normal and find the source of the noises. If the operation is not correct, make reference to the Check List Dur D uring ing Operation for problems and for probable ca uses. 6. Lower the wheels wheels to the ground ground and stop the engine. engine.

76

i02926658

Visual Inspection SMCS - 3060-040 S/N - FBN1-UP S/N - FLY1-UP S/N - JWJ1-UP S/N - KSF1-UP S/N - LBH1-UP S/N - LDH1-UP S/N - LDY1-UP S/N - LJJ1-UP S/N - LKH1-UP S/N - LNH1-UP S/N - LNR1-UP S/N - LRH1-UP S/N - LTG1-UP S/N - LWT1-UP S/N - MTR1-UP S/N - PXR1-UP S/N - RAK1-UP S/N - RDF1-UP S/N - RGS1-UP S/N - SEJ1-UP S/N - SJW1-UP S/N - SKR1-UP

Personal injury or death can c an result from escaping fluid under pressure. Escaping fluid under pressure, even a very ve ry small pin-hole pin-hole size

77

possible death. If fluid is injected into your skin, it must be treated by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Start the engine. engi ne. Run the machine until until the fluids reach normal operating opera ting temperature. tempe rature. Lower the work tools to ols to the groun gro und. d. Lower the stabilizers. Engage the parking brake. Stop the engine. Shift the direction control lever to the NEUTRAL position. Shift the transmission speed control lever to the NEUTRAL position. During the visual check, use a magnet in order to separate ferrous particles from nonferrous particles. 1. Check the oil level in the the transmiss transmission. ion. Look for air ai r (bubbles) or water on the dipstick. dipsti ck. Many problems in i n the the transmission transmissi on are caused by low oil level or air in the oil. Add oil to the transmission if oil is needed. a. Air Ai r (bubbles) is usually caused by a loose tube or a damaged casti ng that that allows air to enter the suction side of the system. The air leak will allow oil to leak. 2. Check all oil lines, hoses and connections for leaks and damage. Look for oi l on the ground ground under under the machine. 3. Move the the direction direc tion control lever lever to the REVERSE and FORWARD forward positions posi tions and move move the transmission transmissi on speed control lever to all SPEED positions. The detents must be felt in each speed position. The actuation of the direction control lever must give the same positive activation to the hydraulic control circuit for clutch engagement in both directions.

Note: There is an oil filter bypass valve on the inlet side of the transmission oil filter. The bypass valve for the oil filter will open and the valve will allow oil to bypass the oil filter element whenever the pressure difference between the inlet oil and the outlet oil through the oil filter gets above 345 kPa (50 psi). Any oil that does not go through the filter element goes directly into the hydraulic circuit. Dirty oil can cause a restriction in the orifices of the valve. This can cause the valve to stick. 4. Drain Drai n the the oil oi l from the transmiss transmission ion case by b y removing the the oil oi l plug and and then remove remove the cover plate from the lower right side of the transmission for further draining of any remaining oil. Remove the suction screen and inspect the suction screen. Also, inspect the bottom of the transmission case for debris. Remove the transmission oil filter and inspect the transmission oil filter for foreign material. a. Rubber particles parti cles indicate seal failure or hose hose failure. b. Shiny steel particles indicate i ndicate mechanical failure or gear wear of the the transmission transmissio n or pump. c. A heavy accumulation of black fiber fibe r material indicate indic ate worn clutch discs. dis cs. d. Aluminum particles partic les indicate indica te a failure of a clutch piston pis ton or torque converter. converter. e. Iron or steel chips chips indicate indi cate broken components in the the transmission. transmissio n.

78

i02438909

Power Train Troubleshooting SMCS - 3060-035-HR; 3101-035 S/N - FBN1-UP S/N - FLY1-UP S/N - JWJ1-UP S/N - KSF1-UP S/N - LBH1-UP S/N - LDH1-UP S/N - LDY1-UP S/N - LJJ1-UP S/N - LKH1-UP S/N - LNH1-UP S/N - LNR1-UP S/N - LRH1-UP S/N - LTG1-UP S/N - LWT1-UP S/N - MTR1-UP S/N - PXR1-UP S/N - RAK1-UP S/N - RDF1-UP S/N - RGS1-UP S/N - SEJ1-UP S/N - SJW1-UP S/N - SKR1-UP


79

This section provides probable causes to known problems. Since there may be several probable causes, specific inspections or instrument tests may be recommended. These inspections and tests will help to identify the causes that are most probable.

Problem The transmission does not operate in any speed or the transmission does not engage in all speeds. Probable Cause 1. The The neutral neutral lockout switch is engaged. 2. The The parking brake is set or the the parking brake switch has has failed. 3. An electrical failure in the the shift control or a damaged transmissi on control control fuse. fuse. 4. Low oil pressure that is a result of the following following causes: a. The The oil level level is low. b. Oil pump failure. c. Air Ai r leaks on inlet side of the the pump. d. The The transmission transmissi on leaks. 5. The The transmission transmissio n has a mechanical failure. a. Clutch discs dis cs and plates have have too much much wear. wear. b. The The seals leak.

Problem The transmission does not shift. Probable Cause 1. Air leaks on inlet inlet side of pump. pump. 2. The The wiring to the solenoid control valve valve is broken brok en or the the wiring is not connected. 3. An electrical failure in shift control or a damaged damage d transmission transmissi on control control fuse. fuse. 4. Low oil pressure.

Problem The transmission gets hot. Probable Cause 1. A temperature temperature gauge gauge is damaged. 2. The The oil level is high. 3. The The core of the the oil cooler is not completely open. 4. The The clutch is slippi sli pping ng too much. much. a. The The oil pressure is low. b. The The clutch clutch is damaged. damaged . 5. Low oil flow as a result of pump pump wear or extra leakage in the hydraulic hydraulic system. 6. The The applicatio appli cation n for the the vehicle vehicle is wrong. A large load causes too much torque converter converter slip. 7. Air is in i n the the oil. Air leaks on intake intake side of pump. pump. 8. The The torque converter converter relief valve is stuck open. 9. The The oil in the the transmissi transmission on is wrong.

Problem

80

Probable Cause 1. Foreign Forei gn material materia l is in the transmission transmissi on hydraulic hydraulic system. 2. A constant loud noise noise is i s an indication indic ation of pump pump failure. 3. There There is a failed suctio n tube or a damaged damage d suction tube. tube.

Problem The transmission has noise that is not normal. Probable Cause 1. Parts have have wear or damage.

Problem The transmission operates in forward speeds only. Probable Cause 1. Wiring Wiri ng to the solenoid solenoid control co ntrol valve valve is broken or the the wiring is not connected. connected. 2. The The shift control is malfunctioning or tthere here is a damaged solenoid. solenoi d. 3. Discs Di scs and plates have have too much much wear wear in reverse direction directi on clutches. clutches. 4. The The seal rings leak. 5. Reverse clutch clutch components have have damage. 6. The The control valve valve gasket has damage. 7. The The forward clutch is warped.

Problem The transmission operates in reverse speeds only. Probable Cause 1. Wiring Wiri ng to the solenoid solenoid control co ntrol valve valve is broken or the the wiring is not connected. connected. 2. The The shift control is malfunctioning or tthere here is a damaged solenoid. solenoi d. 3. Discs Di scs and plates have have too much much wear wear in forward direction directi on clutches. clutches. 4. The The seal rings leak. 5. Forward clutch components have have damage. 6. The The control valve valve gasket has damage. 7. The The reverse clutch clutch is warped.

Problem The Clutch engagement is slow and the transmission makes rough shifts. Probable Cause 1. The The transmiss transmission ion oil pressure is low. 2. The The oil leaks internally. internally. 3. The The solenoid solenoid is sticking.

Problem Oil pressure too low. Probable Cause 1. The The oil level level is low.

81

2. Failure Fai lure of transmission transmissi on oil pump. 3. There There is a suction leak. 4. The The oil in the the transmissi transmission on is wrong.

82

i03419321

Pressure Taps 5 050-025-PWT; 5050-081-PWT SMCS - 3060-025; 3060-081; 5050-025-PWT;

S/N - FBN1-UP S/N - FLY1-UP S/N - JWJ1-UP S/N - KSF1-UP S/N - LBH1-UP S/N - LDH1-UP S/N - LDY1-UP S/N - LJJ1-UP S/N - LKH1-UP S/N - LNH1-UP S/N - LNR1-UP S/N - LRH1-UP S/N - LTG1-UP S/N - LWT1-UP S/N - MTR1-UP S/N - PXR1-UP S/N - RAK1-UP S/N - RDF1-UP S/N - RGS1-UP S/N - SEJ1-UP S/N - SJW1-UP S/N - SKR1-UP The following graphic shows the location of the pressure taps that are used for the testing and adjusting of the direct drive transmission.

83

Illustration 1 Typical Example

g01452640

Two-wheel drive (1) Pump pressure (2) Torque converter inlet (3) Reverse clutch (4) Forward clutch (5) Lubrication pressure

Illustration 2 Typical Example All whe wheel el driv drive (6) Pump pressure

g01452648

84

(8) Reverse clutch (9) Forward clutch (10) Clutch pressure

85

i04638370

Transmission and Torque Converter - Test SMCS - 3060-081-HR; 3101-081 S/N - FBN1-UP S/N - FLY1-UP S/N - JWJ1-UP S/N - KSF1-UP S/N - LBH1-UP S/N - LDH1-UP S/N - LDY1-UP S/N - LJJ1-UP S/N - LKH1-UP S/N - LNH1-UP S/N - LNR1-UP S/N - LRH1-UP S/N - LTG1-UP S/N - LWT1-UP S/N - MTR1-UP S/N - PXR1-UP S/N - RAK1-UP S/N - RDF1-UP S/N - RGS1-UP S/N - SEJ1-UP S/N - SJW1-UP S/N - SKR1-UP Table 1

Required Tools Part Number

Tools

Qty

6V-3121 6V-312 1

Multitach

1

86

198-4240

Digi tal Pressure Indicator

1

6V-3965 Fitting As must be installed into the transmission in order to perform some tests.

Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the procedure that follows before the test is done. Note: For all tests, the machine must be at operating temperature. Table 2

Transmission Transmission Pressure Test Test Points

2 Wheel Drive

Pump Pressure at High Idle

1500 ± 250 kPa (220 ± 35 psi)

Forward Clutch Pressure at Low Idle

1350 ± 300 kPa (195 ± 44 psi)

Reverse Clutch Pressure at Low Idle

1350 ± 300 kPa (195 ± 44 psi)

Lubrication Pressure at High Idle Pressure for the All Wheel Drive Dri ve Clutch

All Wheel Drive

50 to 500 kPa (7 to 75 psi) psi ) N/A

1350 ± 300 kPa (195 ± 44 psi)

Removal of the Floorplate The following components must be removed before the transmission system can be tested.

Illustration 1

g01399031

Illustration 2

g00759467

87

Illustration 3

g01399012

2. Remove two bolts (3) and and plate (4). Repeat for the other other side. side . Remove floor mat (7) .

Illustration 4

g01399025

3. Remove six bolts (8) from the the perimeter perimete r of the the floorplate. Place floorplate (9) aside. asi de.

Illustration 5

g02783325

88

Illustration 6 g02783337 The machine ECM (11) is under floorplate (10) .

4. Remove six bolts (8) from the perimeter peri meter of floorplate floorplate (10). Place floorplate (10) aside. asid e. 5. Proceed Procee d to the the appropri ate test that that is required. required . Reinstall the plates, screws, and and the mats to the the cab when testing is completed. comp leted.

Test for the Transmission Oil Pump Pressure This test will show if the transmission oil pump is good.

Illustration 7 Typical example Two-wheel drive (1) Pump pressure (2) Torque converter inlet (3) Reverse clutch pressure tap (4) Forward clutch pressure tap (5) Lubrication pressure tap

g01454107

89

Illustration 8 Typical example

g01521241

All whe wheel el driv drive (6) Pump pressure (7) Torque converter inlet (8) Reverse clutch pressure tap (9) Forward clutch pressure tap (10) Lubrication pressure tap (11) Pressure tap for the all wheel drive

Illustration 9 (12) Transmission speed control (13) Direction control lever

g02783556

90

1. At pressure tap (1) or (6), connect connect 198-4240 Di gital Pressure Indicator Indicator . 2. Place the direction directi on control control Lever (13) in NEUTRAL. Also place the transmission transmissi on speed control (12) in NEUTRAL. 3. Activate Acti vate the the parking parki ng brake. Start the engine engine and run the engine engine at low idle. 4. Shift direction direc tion control lever lever (13) to FORWARD. Run the engine engine at high idle. The pressure must be 1500 ± 250 kPa kP a (220 ± 35 psi). 5. When this test is complete, complete , reduce the the engine speed to low idle. id le. Place the directi on control lever in NEUTRAL. NEUTRAL. Stop the engine and remove the equipment.

Test for the Torque Converter Stall The test will show if engine performance is good. The test will show if the torque converter operates properly. Also, the test will show if there is oil flow through the oil cooler.

Note: Any unus unusual ual noises noises durin during g this this check check shou should ld be noted. noted. Loud Loud noises noises coul could d indicate indicate that that repairs are needed. needed. 1. Start the engine engine and run the engine engine at low idle.

Illustration 10

g01228983

2. Place the bucket hydraulic hydraulic controls in the lowering position. posi tion. Lift the front wh wheels eels about abo ut 150 mm (6 inch) off the the ground and support the front axle with suitable jack stands. 3. Lift the rear wheels about 150 mm (6 inch i nch)) off the ground ground and support the rear axle with suitable jack stands. s tands. 4. Stop the engine and proceed procee d with the following procedure. 5. Install Install the 6V-3121 Multitach on the engine. The multitach can measure engine speed by the use of a photo pickup and reflective tape. The Special Instruction, SEHS7807 has instructions for the use of the multitach.

91

Illustration 11 (1) Transmission speed control

g02783937

(2) Direction control lever (3) All wheel drive switch

6. With the the transmission transmissio n speed control co ntrol (1) in (NEUTRAL) (NEUTRAL) position, posi tion, start the the engine.

NOTICE To ensure that the transmission oil does not overheat, do not keep the torque converter in a full stall condition for more than 30 seconds. After After the torque converter stall test, reduce the engine speed to low idle. In order to cool the oil, move the transmission control to the NEUTRAL position and run the engine between 1200 rpm and 1500 rpm.

7. Run the engine at low idle. Fully engage the brakes. Run the the transmission transmissi on at normal operating temperature 70° ± 10°C 1 0°C (158° (158 ° ± 18°F). Shift the transmission speed control (1) to FOURTH SPEED. Shift the direction control lever (2) to FORWARD. Increase engine speed to high-idle and stall the torque converter until the temperature for the torque converter reaches 110° C (230° F). Record the stall speed at approximately 110° C (230° F).

Note: Follow the steps below in order to verify the transmission operating temperature: Turn Turn the FRONT Lights ON and OFF four fo ur times Record the temperature that appears on the display in place of the hour meter. The tables that follow contain the correct stall RPM for the various horsepower ratings of the engines that are installed in machines. Refer to table 3 for machines with standard transmissions. Table 3

Standard Transmission Transmission Stall Speed (RPM) Model Minim inimum um Maxim aximum um 422F 2019

2350

2180

2350

56.0 kW (75 hp) 428F 68.5 kW (92 hp)

92

434F 2155

2350

1965

2206

68.5 kW (92 hp) 444F 74.5 kW (100 hp) 8. When the test is complete, put the the direction dire ction control lever lever (2) in NEUTRAL NEUTRAL and the transmiss transmission ion speed control co ntrol (1) (1) in NEUTRAL. Stop the engine and remove the test equipment.

Note: Do not keep the torque converter in a stall condition for long periods of time. The torque converter and the engine will get hot. Problem The oil gets too hot during normal operation. Probable cause Not enough oil is in the torque converter because the inlet relief valve for the torque converter is open. The oil pump fails. The The torque conv co nverter erter fails. fai ls. The temperature gauge is bad. Replace the temperature gauge and the sending unit. The air flow to the oil cooler is blocked by debris. Debris could also be blocking air flow to the engine cooler.

Problem High idle is correct, but stall speed is too high. Probable cause The torque converter is bad.

Problem Stall speed is low. Probable cause There is an engine problem.

Test for Clutch Oil Pressure and Transmission Lubrication

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Illustration 12 Typical example

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Two-wheel drive (1) Pump pressure (2) Torque converter inlet (3) Reverse clutch pressure tap (4) Forward clutch pressure tap (5) Lubrication pressure tap

Illustration 13 Typical example All whe wheel el driv drive (6) Pump pressure

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94

(8) Reverse clutch pressure tap (9) Forward clutch pressure tap (10) Lubrication pressure tap (11) Pressure tap for the all wheel drive


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This test will show if oil pressure to the forward clutch and the pressure to the reverse clutch is good. The test will also show if the transmission transmission lubrication circuit is good. 1. Install Install the 6V-3121 Multitach on the engine. engi ne. The 6V-3121 Multitach can measure the engine speed by the use of the photo pickup and the reflective tape. The instructions for the use of the photo pickup and reflective tape are in Special Instruction, SEHS7807. 2. At pressure taps (3) and (4) or pressure taps (8) and and (9), connect connect 198-4240 Di gital Pressure Indicator Indicator . 3. At pressure tap (5) or (11), connect connect 198-4240 Digital Di gital Pressure Indicator Indicator . 4. Start the engine engine and run the engine engine at low idle. 5. Shift the direction directio n control control lever (13) (13) to REVERSE, REVE RSE, and shift the the transmission transmissi on speed control (12) to NEUTRAL. Reverse Reverse clutch pressure pressure tap (3) or (8) must be 1350 ± 300 kPa (195 ± 44 psi). psi ). The The lubrication pressure pressure tap (5) or (11) must must be 275 ± 225 kPa (40 ± 33 3 3 psi). Forward Fo rward clutch clutch pressure pressure tap (4) or (9) must must be 0 kPa (0 psi ). 6. Now shift the the direction dire ction control lever (13) to FORWARD, and the transmission speed control c ontrol (12) to NEUTRAL. NEUTRAL. Forward clutch pressure pressure tap (4) or (9) must be 1350 ± 300 kPa (195 ± 44 psi). psi ). The The lubrication pressure pressure tap (5) or (11) must must be 275 ± 225 kPa (40 ± 33 psi). The reverse clutch pressure tap (3) or (8) must be 0 kPa (0 psi). 7. When the test is complete, put the the direction dire ction control lever lever in NEUTRAL, and and engage the parking brakes. brake s. Stop the engine. Remove the test equipment.

Problem Both forward clutch pressure and reverse clutch pressure is too low. Probable Cause The spring to the system relief valve is weak.

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The oil filter is plugged. Replace the dirty oil filter. Oil pump failure. The The neutralizer button that that is i s on the shift lever or the tilt ti lt control lever shorted. This issue is sue caused the solenoid so lenoid control co ntrol valve valve to deenergize. The clutch piston seals are bad.

Problem Either the forward clutch pressure or the reverse clutch pressure is too low. Probable Cause The The solenoid solenoi d is i s faulty. The clutch piston seals are bad. The seals are faulty or the seals are missing on the input shaft.

Test for the All Wheel Drive (if equipped)

Illustration 15 Typical example All whe wheel el driv drive (1) Pump pressure (2) Torque converter inlet (3) Reverse clutch pressure tap (4) Forward clutch pressure tap (5) Lubrication pressure tap (6) Clutch pressure tap

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96


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1. At lubrica lubrication tion pressure tap tap (6), connect 198-4240 Digital Di gital Pressure Indicator Indicator . 2. Start the engine engine and run the engine engine at low idle. 3. Engage all wheel drive by pressing pressi ng the the left side of the all wheel wheel drive dri ve switch (9). The The pressure for the all wheel wheel drive must be 1350 ± 300 kPa (195 ± 44 psi). 4. When the the test is complete, comple te, press the right sid side e of all wheel drive switch (9). This This function will return the machine to the the two-wheel drive mode. Engage the parking brakes. 5. Stop the the engine. 6. Remove the test equipment.

416F-444F Transmission (Standard Shift) UENR2302

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