Transmision 416

416D Backhoe Loader B2D00001-UP (MACHINE) POWERED BY 3054C Engine(SEBP4184 - 22) - Estructura del documento
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Producto: BACKHOE LOADER Modelo: 416D BACKHOE LOADER B2D Configuracin: 416D Backhoe Loader B2D00001-UP (MACHINE) POWERED BY 3054C Engine
Pruebas y Ajustes
416D, 420D, 424D, 428D, 430D, 432D, 438D and 442D Backhoe Loaders Transmission (Direct Drive)
Nmero de medio -RENR3574-05 Fecha de publicacin -01/10/2005 Fecha de actualizacin -10/10/2005
i03385128
Pressure Taps
SMCS - 3060-025; 3060-081; 5050-025-PWT; 5050-081-PWT The following graphic shows the location of the pressure taps that are used for the testing and adjusting of the direct drive transmission.
Illustration 1 (1) Pump pressure
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(2) Torque converter inlet (3) Reverse clutch (4) Forward clutch (5) Lubrication pressure (6) All wheel drive (if equipped)
The graphic shows plugs at locations (2-3-4-6) . The plugs must be removed in order to install the pressure taps.
Copyright 1993 - 2011 Caterpillar Inc. Todos los derechos reservados. Red privada para licenciados del SIS. Wed May 18 21:14:33 UTC-0400 2011
416D Backhoe Loader B2D00001-UP (MACHINE) POWERED BY 3054C Engine(SEBP4184 - 22) - Estructura del producto
Cerrar SIS
Pantalla anterior
Desarmado y Armado
Nmero de medio -RENR3578-11
416D, 420D, 424D, 428D, 430D, 432D, 438D and 442D Backhoe Loaders Power Train
Fecha de publicacin -01/09/2009 Fecha de actualizacin -29/09/2009
i01381641
Transmission (Direct Drive) - Assemble

SMCS - 3030-016-DD; 3066-016
Assembly Procedure
Table 1 Required Tools Tool A B C D E F Part Number 137-8102 1P-1859 4C-3652 6V-2157 8T-5096 1U-5750 Part Description Spring Compressor Snap Ring Pliers Spring Compressor Link Bracket Indicator Engine Stand Qty 1 1 1 1 1 1
Note: The transmission will be assembled in major components. The major components will then be assembled. Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Note: Apply a light film of clean transmission oil to all components before assembly.
Transmission case
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Illustration 1
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Note: Install the shims behind each bearing cup that was recorded on the disassembly procedure. 1. Install bearing cups (60), (61), (62), (63), and (64) .
(Direct Drive) Input Shaft
Illustration 2
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1. Install the needle thrust bearings on the shafts. The open end of cups (1) must point away from the bearings or gears that are contacted.
Illustration 3
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2. Install the seals on piston (56) .
Illustration 4
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3. Install piston (56). Install the retainer and spring (55). Use tooling (A) and a suitable press in order to compress spring (55). Use tooling (B) in order to install snap ring (54) .
Illustration 5
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4. Install clutch pack (53) and retainer (52) . 5. Repeat Steps 2 through 4 for the opposite end of the input shaft.
Illustration 6
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6. Install gear (51), needle bearing (50), and spacer (49). Use tooling (B) in order to install snap ring (48) .
Illustration 7
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7. Heat bearing cone (57) to 135 C (275 F). Install bearing cone (57) . 8. Install the input shaft.
(Direct Drive) Reverse Shaft
Illustration 8
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1. Heat bearing cones (45) and (46) to 135 C (275 F). Install bearing cones (45) and (46) . 2. Install the reverse shaft.
(Direct Drive) Shaft
Illustration 9
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1. Heat bearing cones (45) and (46) to 135 C (275 F). Install bearing cones (45) and (46) . 2. Install the shaft.
(Direct Drive) Output Shaft (Rear)
Illustration 10
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1. Install gear (42) .
Illustration 11
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2. Install housing (41) and gear (40). Use tooling (B) in order to install snap ring (39) .
Illustration 12
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3. Install synchronizer (38). Install gear (37). Heat bearing cone (36) to 135 C (275 F). Install bearing cone (36) .
Illustration 13
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4. Install synchronizer (35), spacer (34), and bearings (33) .
Illustration 14
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5. Install gear (31) and (32). Heat bearing cone (30) to 135 C (275 F). Install bearing cone (30) . 6. Install the output shaft (rear) in the transmission.
Illustration 15
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Illustration 16
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7. Install two gearshift rods (23) on shift forks (29). Install the gearshift rods in the transmission. Install three balls (28), two springs (27), and O-ring (26). Install plug (25) .
Illustration 17
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8. Install screws (24) on each of the gearshift rods (23) .
(Direct Drive) Output Shaft (Front)
Illustration 18
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1. Install seals on piston (22) .
Illustration 19
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Illustration 20
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2. Install piston (22), spring (19), and retainer (21) . 3. Use tooling (C) and a suitable press in order to compress spring (19). Use tooling (B) in order to install snap ring (20) .
Illustration 21
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4. Install clutch pack (18) and retainer (17) .
Illustration 22
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5. Install thrust washer (16), needle bearing (15), spacer (14), and two roller bearings (13) .
Illustration 23
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6. Heat bearing cone (11) to 135 C (275 F). Install bearing cone (11) .
Illustration 24
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7. Heat bearing cone (10) to 135 C (275 F). Install bearing cone (10) .
Illustration 25
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8. Install front output shaft (9) .
Final Assembly
Illustration 26
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Note: Clean the mating surfaces of case (7). Apply a continuous bead of 1U-8846 Sealant to the mating surface of the case. 1. Attach tooling (D) to case (7). Attach a suitable lifting device to tooling (D). Use fourteen bolts (8) in order to install case (7). The weight of case (7) is 42 kg (94 lb).
Illustration 27
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2. Install a bolt in the output shaft. The output shaft must be fully seated. Install tooling (E), as shown. Zero tooling (E). Pry up on the bolt and record the reading on tooling (E). The reading must be 0.03 mm (0.0012 inch) to 0.08 mm (0.0031 inch). Add or remove shims in Step 1 in the Case Assembly Procedure in order to obtain the correct reading.
Illustration 28
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3. Repeat Step 1 for the input shaft and the output shaft (front). Use the same tolerance for all of the shafts. Remove the expansion plug in order to check the input shaft. Use a screwdriver to pry up on the input shaft. Install a new 1H-9721 Expansion Plug .
Illustration 29
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4. Install yoke (4), washer (5), and bolt (6) .
Illustration 30
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5. Install plug (3) .
Illustration 31
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6. Install Implement pump drive shaft (2) in transmission (1) .
Illustration 32
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7. Remove transmission (1) from tooling (F) . End By: Install the transmission. Refer to Disassembly and Assembly, "Transmission (Direct Drive) Install".
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Pantalla anterior
Desarmado y Armado
i01380368
Transmission (Direct Drive) - Disassemble

SMCS - 3030-015-DD; 3066-015
Disassembly Procedure
Table 1 Required Tools Tool A B C C C D E F G G H H I J K Start By: A. Remove the transmission. Refer to Disassembly and Assembly, "Transmission (Direct Drive) Remove". 4C-3652 1U-6405 4C-3802 8H-0663 5F-7465 8B-7551 6V-3010 137-8102 4C-3089 1P-1859 Part Number 1U-5750 6V-2157 9S-9152 5F-7465 Part Description Engine Stand Link Bracket Puller Assembly Puller 3/8inch x 6inch Bolt Spring Compressor Puller Puller Puller Puller Puller Puller Spring Compressor Puller Snap Ring Pliers Qty 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1
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 Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism. Note: The transmission will be disassembled in major components. The major components will then be disassembled.
Illustration 1
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1. Install transmission (1) on tooling (A) .
Illustration 2
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2. Remove Implement pump drive shaft (2) from transmission (1) .
Illustration 3
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3. Remove plug (3). Drain the transmission oil into a suitable container. The capacity of the transmission is 11.3 L (3 US gal).
Illustration 4
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4. Remove bolt (6), washer (5), and yoke (4) .
Illustration 5
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5. Attach tooling (B) to case (7). Attach a suitable lifting device to tooling (B). Remove fourteen bolts (8). Remove case (7) from the transmission. The weight of case (7) is 42 kg (94 lb).
(Direct Drive) Output Shaft (Front)
Illustration 6
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1. Remove front output shaft (9) .
Illustration 7
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2. Use tooling (C) in order to remove bearing cone (10) .
Illustration 8
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3. Use tooling (E) in order to remove bearing cone (11) and gear (12) .
Illustration 9
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4. Remove two roller bearings (13), spacer (14), needle bearing (15), and thrust washer (16) .
Illustration 10
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5. Remove retainer (17) and clutch pack (18) .
Illustration 11
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6. Use a suitable press and tooling (D) in order to compress spring (19). Use tooling (K) in order to remove snap ring (20) .
Illustration 12
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7. Remove snap ring (20), retainer (21), and spring (19) .
Illustration 13
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8. Release piston (22) by blowing shop air into the lube passage, as shown.
Illustration 14
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9. Use a seal pick in order to remove the seals from piston (22) .
(Direct Drive) Output Shaft (Rear)
Illustration 15
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1. Remove screws (24) from each of the gearshift rods (23) .
Illustration 16
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2. Remove plug (25) .
Illustration 17
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3. Remove plug (25), O-ring (26), two springs (27), and three balls (28). Remove two gearshift rods (23) from shift forks (29) .
Illustration 18
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4. Use tooling (E) in order to remove bearing (30), gear (31), and gear (32) .
Illustration 19
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5. Remove bearings (33), spacer (34), and synchronizer (35) .
Illustration 20
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6. Use tooling (F) in order to remove bearing (36) and gear (37). Remove synchronizer (38) .
Illustration 21
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7. Use tooling (K) in order to remove snap ring (39). Remove gear (40) and housing (41) .
Illustration 22
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8. Use tooling (E) in order to remove gear (42) .
(Direct Drive) Shaft

1. Remove the shaft by hand for disassembly.
Illustration 23
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2. Use tooling (G) in order to remove bearings (43) and (44) .
(Direct Drive) Reverse Shaft

1. Remove the reverse shaft by hand for disassembly.
Illustration 24
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2. Use tooling (G) in order to remove bearings (45) and (46) .
(Direct Drive) Input Shaft

1. Remove the input shaft by hand for disassembly.
Illustration 25
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2. Use tooling (H) in order to remove bearing (47) .
Illustration 26
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3. Use tooling (K) in order to remove snap ring (48). Remove spacer (49), needle bearing (50), and gear (51) .
Illustration 27
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4. Remove retainer (52) and clutch pack (53) .
Illustration 28
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5. Use tooling (I) and a suitable press in order to compress spring (55). Use tooling (K) in order to remove snap ring (54). Remove the retainer and spring (55) .
Illustration 29
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6. Release piston (56) by blowing shop air into the lube passage, as shown.
Illustration 30
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7. Use a seal pick in order to remove the seals from piston (56) .
Illustration 31
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8. Use tooling (J) in order to remove bearing (57) and gear (58) .
Illustration 32
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9. Remove gear (59) from the clutch pack. 10. Repeat Steps 4 through 7 for the remainder of the input shaft.
Transmission Case
Illustration 33
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Note: Record the measurement and placement of the shims behind the bearing cups in order to
aid in assembly. 1. Remove bearing cups (60), (61), (62), (63), and (64) .
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Pantalla anterior
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i01457233
Transmission (Direct Drive) - Remove

SMCS - 3030-011-DD
Removal Procedure
Table 1 Required Tools Tool Part Number 8S-7640 A 8S-7611 8S-7615 B C D E Start By: A. Remove the front drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Front) - Remove and Install". B. Remove the rear drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Rear) - Remove and Install". C. Remove the piston pump. Refer to Disassembly and Assembly, RENR3585, "Piston Pump (Implement and Steering) - Remove". 1. Use a suitable lifting device in order to raise the machine to a height of 91.4 mm (36 inch) between the ground and the side step. 1U-9760 1U-7505 1U-7558 FT-2535 Part Description Stand Tube Pin Jack Stand Transmisson Jack Mounting Brackets Engine Support Bar Assembly Qty 2 2 2 2 1 2 1
Illustration 1
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2. Place tooling (A) under rear frame (1) .
Illustration 2
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3. Place tooling (B) under front axle (2) .
Illustration 3
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4. Remove inspection plate (3). Install tooling (E) in order to support the engine.
Illustration 4
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5. Remove plug (4) and drain the transmission oil into a suitable container. The capacity of the transmission is 18.5 L (4.9 US gal).
Illustration 5
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6. Remove four bolts (5) . 7. Repeat Step 6 for the opposite side. 8. Remove two bolts (6) .
Illustration 6
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9. Disconnect three electrical connectors (7) .

Illustration 7
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10. Loosen bolt (8) and slide rod assembly (9) off the transmission lever.
Illustration 8
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Illustration 9
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11. Support transmission (10) with tooling (C), as shown. 12. Attach tooling (D) to tooling (C) and transmission (10) in order to maintain a good balance.
Illustration 10
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13. Remove fourteen bolts (11) . 14. Carefully move transmission (10) away from the engine in order to clear the torque converter. Lower transmission (10) to the ground. The weight of transmission (10) is 185 kg (408 lb).
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Pruebas y Ajustes
416D, 420D, 424D, 428D, 430D, 432D, 438D and 442D Backhoe Loaders Transmission (Direct Drive)
Nmero de medio -RENR3574-05 Fecha de publicacin -01/10/2005 Fecha de actualizacin -10/10/2005
i02425361
Transmission and Torque Converter - Test

SMCS - 3060-081-HR; 3101-081 Table 1 Required Tools Part Number 6V-3121 6V-3965 198-4240 Tools Needed Multitach Fitting As Digital Pressure Indicator Qty 1 3 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 Pressure Test Test Points Pump Pressure at High Idle Forward Clutch Pressure at Low Idle Reverse Clutch Pressure at Low Idle Lubrication Pressure at Low Idle 2 Wheel Drive All Wheel Drive
1525 175 kPa (220 25 psi) 1410 100 kPa (205 15 psi) A result within 25 kPa (3.6 psi) of Forward clutch pressure 120 90 kPa (17 13 psi)
Pressure for the All Wheel Drive Clutch
N/A
1410 100 kPa (205 15 psi)
Removal of the Floorplate

The following components must be removed before the transmission system can be tested.
Illustration 1
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1. Remove ten bolts (2) and cover (1) .
Illustration 2
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2. Remove two bolts (3) and plate (4) .
Illustration 3
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3. Remove two bolts (5) and plate (6) . Remove floor mat (7) .
Illustration 4
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4. Remove four bolts (8) and set the floorplate (9) aside. 5. Proceed to the appropriate test that is required. Reinstall the plates, screws and the mats to the cab when testing is completed.
Test for the Transmission Oil Pump Pressure

This test will show if the transmission oil pump is good.
Illustration 5 (10) Transmission pump pressure
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1. At pressure tap (10) , connect 198-4240 Digital Pressure Indicator . 2. Place the direction control lever in NEUTRAL. Also place the speed shift lever in NEUTRAL. 3. Activate the parking brake. Start the engine and run the engine at low idle. 4. Shift the direction control lever to FORWARD. Run the engine at high idle. The pressure should be approximately 1525 175 kPa (220 25 psi). 5. When this test is complete, reduce the engine speed to low idle. Place the direction control lever in 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 unusual noises during this check should be noted. Loud noises could indicate that repairs are needed. 1. Start the engine and run the engine speed at low idle. 2. Lower the stabilizers and lift the rear wheels about 150 mm (6 inch) off the ground. 3. Place the bucket hydraulic controls in the lowering position. Lift the front wheels about 150 mm (6 inch) off the ground. 4. Stop the engine and proceed with the following procedure. 5. 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 Instructions, SEHS7807 has instructions for the use of the multitach. 6. With the transmission shift lever in (NEUTRAL) position, start the engine and run the engine at low idle. Ensure that high idle rpm and low idle rpm are correct. Refer to Engine supplement, SENR5815, "3054 Engines for Caterpillar Built Machines".
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 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 high idle. Fully engage the brakes. Run the transmission at normal operating temperature 59 to 71C (138 to 160F). Shift the speed shift lever to FOURTH SPEED. Shift the direction control lever to FORWARD and stall the torque converter until the temperature of the converter reaches 90 to 93C (194 to 200F). Table 4 contains the correct stall RPM for the various horsepower ratings of the engines that are installed in machines. Table 3 Direct Drive Transmission Arrangement Horsepower Rating Stall RPM
75 hp 80 hp 85 hp 93 hp
2084 75 RPM 2143 75 RPM 2210 75 RPM 2247 75 RPM
Note: Stall speeds are calculated using No. 2 diesel fuel. 8. When the test is complete, put the direction control lever in NEUTRAL and the shift lever in NEUTRAL. Stop the engine and remove the test equipment. Note: Do not keep the torque converter in a stall condition for very long periods of time. The torque converter, the engine, and the brakes will get hot. Problem The oil gets too hot during normal operation. Probable cause 1. Not enough oil is in the torque converter because the inlet relief valve for the torque converter is open. 2. The oil pump fails. 3. The torque converter fails. 4. The temperature gauge is bad. Replace the temperature gauge and the sending unit. 5. 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 1. The torque converter is bad. Problem Stall speed is low. Probable cause 1. There is an engine problem.
Test for Clutch Oil Pressure and Transmission Lubrication

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 lubrication circuit is good. 1. Install the 6V-3121 Multitach on the engine. 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.
Illustration 6 (12) Forward clutch pressure (13) Reverse clutch pressure
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2. At pressure taps (12) and (13) , connect 198-4240 Digital Pressure Indicator .
Illustration 7
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3. At pressure tap (14) , connect 198-4240 Digital Pressure Indicator . 4. Start the engine and run the engine at low idle. 5. Shift the direction control lever to FORWARD, and shift the speed shift lever to NEUTRAL. The pressure for the forward clutch should be approximately 1410 100 kPa (205 15 psi). The lubrication pressure must be 120 90 kPa (17 13 psi). The reverse clutch pressure should be 0 kPa (0 psi). 6. Now shift the direction control lever to REVERSE, and shift the speed shift lever to NEUTRAL. The reverse clutch pressure shall be within 25 kPa (3.5 psi) of the pressure in the FORWARD at the same engine speed. The lubrication pressure should be approximately 120 90 kPa (17 13 psi). The forward clutch pressure should be 0 kPa (0 psi). 7. When the test is complete, put the direction control lever in NEUTRAL, and engage the parking brakes. Stop the engine. Remove the test equipment. Problem Both forward clutch pressure and reverse clutch pressure is too low. Probable Cause
1. The spring to the system relief valve is weak. 2. The oil level is low. 3. The oil filter is plugged. Replace the dirty oil filter. 4. Oil pump failure. 5. The neutralizer button that is on the shift lever or the tilt control lever shorted. This caused the solenoid control valve to de-energize. 6. The clutch piston seals are bad. Problem Either the forward clutch pressure or the reverse clutch pressure is too low. Probable Cause 1. The solenoid is faulty. 2. The clutch piston seals are bad. 3. The seals are faulty or the seals are missing on the input shaft.
Test for the All Wheel Drive (if equipped)
Illustration 8 (15) All wheel drive pressure
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1. At pressure tap (15) , connect 198-4240 Digital Pressure Indicator . 2. Start the engine and run the engine at low idle.
Illustration 9 (16) All wheel drive switch
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3. Engage the all wheel drive by pressing the left side of the all wheel drive switch (16) . The pressure for the all wheel drive should be approximately 1410 100 kPa (205 15 psi). 4. When the test is complete, press the right side of the all wheel drive switch (16) in order to return the machine to the two-wheel drive mode, and engage the parking brakes. Stop the engine. Remove the test equipment.

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416D Backhoe Loader B2D00001-UP (MACHINE) POWERED BY 3054C Engine(SEBP4184 - 22) - Estructura del documento

Illustration 1 (1) Pump pressure

Transmission (Direct Drive) - Assemble

(Direct Drive) Input Shaft

2. Install the seals on piston (56) .

(Direct Drive) Reverse Shaft

(Direct Drive) Shaft

(Direct Drive) Output Shaft (Rear)

1. Install gear (42) .

4. Install synchronizer (35), spacer (34), and bearings (33) .

8. Install screws (24) on each of the gearshift rods (23) .

(Direct Drive) Output Shaft (Front)

1. Install seals on piston (22) .

4. Install clutch pack (18) and retainer (17) .

8. Install front output shaft (9) .

4. Install yoke (4), washer (5), and bolt (6) .

5. Install plug (3) .

6. Install Implement pump drive shaft (2) in transmission (1) .

Transmission (Direct Drive) - Disassemble

1. Install transmission (1) on tooling (A) .

2. Remove Implement pump drive shaft (2) from transmission (1) .

4. Remove bolt (6), washer (5), and yoke (4) .

(Direct Drive) Output Shaft (Front)

1. Remove front output shaft (9) .

2. Use tooling (C) in order to remove bearing cone (10) .

5. Remove retainer (17) and clutch pack (18) .

7. Remove snap ring (20), retainer (21), and spring (19) .

(Direct Drive) Output Shaft (Rear)

1. Remove screws (24) from each of the gearshift rods (23) .

2. Remove plug (25) .

5. Remove bearings (33), spacer (34), and synchronizer (35) .

8. Use tooling (E) in order to remove gear (42) .

(Direct Drive) Shaft

1. Remove the shaft by hand for disassembly.

2. Use tooling (G) in order to remove bearings (43) and (44) .

(Direct Drive) Reverse Shaft

2. Use tooling (G) in order to remove bearings (45) and (46) .

(Direct Drive) Input Shaft

2. Use tooling (H) in order to remove bearing (47) .

4. Remove retainer (52) and clutch pack (53) .

Transmission (Direct Drive) - Remove

2. Place tooling (A) under rear frame (1) .

3. Place tooling (B) under front axle (2) .

9. Disconnect three electrical connectors (7) .

Transmission and Torque Converter - Test

Pressure for the All Wheel Drive Clutch

1410 100 kPa (205 15 psi)

Removal of the Floorplate

1. Remove ten bolts (2) and cover (1) .

2. Remove two bolts (3) and plate (4) .

Test for the Transmission Oil Pump Pressure

Illustration 5 (10) Transmission pump pressure

Test for the Torque Converter Stall

2084 75 RPM 2143 75 RPM 2210 75 RPM 2247 75 RPM

Test for Clutch Oil Pressure and Transmission Lubrication

Illustration 6 (12) Forward clutch pressure (13) Reverse clutch pressure

Test for the All Wheel Drive (if equipped)

Illustration 8 (15) All wheel drive pressure

Illustration 9 (16) All wheel drive switch

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