CATERPILLAR ELPHINSTONE PTY. LTD. R1600 LHD R1600 LHD R1600 LHD R1600 LHD R1600 LHD Ser Ser Ser Ser Service T vice T vice T vice T vice Training Guides raining Guides raining Guides raining Guides raining Guides Help Help Menu Menu Exit Exit POWER TRAIN POWER TRAIN
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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
5
(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.
1
2. Torque converter outlet relief valve.
2
3. Converter lock up clutch control valve.
3
4
4. Converter scavenge pump.5. Transmission pump.
5
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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8
5
1
3
2
4
6
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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
PUMP
TOLOCKUPCLUTCH
PRESSUREREDUCTION
VALVELOCKUP
SOLENOID
SHUTTLEVALVE
SELECTORPISTON
LOADPISTON
MODULATIONREDUCTION
VALVE
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
• 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
• Lubrication isprovided by splashfeed from returnoil in the bottom ofthe case
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41 32
75 6
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
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.
2
1
3
4
5. Component location.
5
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.
1
2. Auto/manual transmission switch.
3. Remote control switch.
3
4. Ride control switch.
4
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.
43
1
5
5. Transmission neutraliser switch.
2. Transmission speed sensor.
2
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.
2
3
45
1
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.