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Cerrar SIS

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Producto: BACKHOE LOADER


Modelo: 428C BACKHOE LOADER 2CR
Configuración: 428C Backhoe Loader Side Shift, Parallel Lift 2CR00001-16211 (MACHINE) POWERED BY 3054 Engine

Pruebas y Ajustes
416C, 426C, 428C, 436C, AND 438C BACKHOE LOADERS POWERSHIFT
Número de medio -SENR1273-00 Fecha de publicación -01/02/1998 Fecha de actualización -01/11/2007

SENR12730005

Testing And Adjusting


SMCS - 3175-025

Troubleshooting The Transmission Hydraulic


System
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, do the checks and tests in the order
they are given. 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 testing and adjusting
the transmission and powertrain. When testing and adjusting the
transmission and powertrain, move the machine to an area clear of
obstructions with ventilation for the exhaust.

1. Move the machine to a smooth horizontal location. Move away from working machines and
personnel.

2. Put the transmission direction control lever in the NEUTRAL position.

3. Activate the neutral lockout switch. Stop the engine.

4. Permit only one operator on the machine. Keep all other personnel either away from the machine
or in view of the operator.

5. Activate the parking brakes.

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6. Lower the buckets or implements (loader and backhoe) and stabilizers to the ground.

7. Make sure all hydraulic pressure is released before any fitting, hose or component is loosened,
tightened, removed or adjusted.

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 where a problem can be and
what repairs are needed. Normally, more or other repair work is needed beyond the
recommendations on the list.

Remember that a problem is not necessarily caused only by one part, but by the relation of one part
with other parts. This list cannot give all possible problems and corrections. The serviceman must
find the problem and its source, then make the necessary repairs.

Always make visual checks first. Check the operation of the machine and then check with
instruments.

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Two-Wheel Drive

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Transmission Hydraulic System in Neutral (Engine Running)


(1) Clutch 1. (2) Clutch 1 solenoid. (3) Forward Low Clutch. (4) Forward low clutch solenoid. (5) Forward high clutch.
(6) Reverse clutch solenoid. (7) Reverse clutch. (8) Clutch 2. (9) Clutch 2 solenoid. (10) Clutch 3. (11) Torque
converter. (12) Oil Filter with bypass. (13) Pump test point. (14) Cold start valve. (15) Lube pressure test port. (16) Oil
pump. (17) Oil cooler. (18) Thermostat bypass valve. (19) Suction screen. (20) Temperature sender. (21) Torque
converter outlet pressure port. (22) Torque converter inlet pressure override valve. (23) Pressure regulator valve. (24)
Clutch 3 solenoid. (25) Forward high Clutch solenoid.

All-Wheel Drive

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Transmission Hydraulic System in Neutral (Engine Running)


(1) All-wheel drive solenoid. (2) All-wheel drive clutch. (3) Clutch 1. (4) Clutch 1 solenoid. (5) Forward Low Clutch.
(6) Forward low clutch solenoid. (7) Forward high clutch. (8) Reverse clutch solenoid. (9) Reverse clutch. (10) Clutch 2.
(11) Clutch 2 solenoid. (12) Clutch 3. (13) Torque converter. (14) Oil Filter with bypass. (15) Pump test point. (16) Cold
start valve. (17) Lube pressure test port. (18) Oil pump. (19) Oil cooler. (20) Thermostat bypass valve. (21) Suction
screen. (22) Temperature sender. (23) Torque converter outlet pressure port. (24) Torque converter inlet pressure
override valve. (25) Pressure regulator valve. (26) Clutch 3 solenoid. (27) Forward high Clutch solenoid.

Location Of Pressure Taps

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(A) Pressure tap for pump pressure. (B) Pressure tap location for lube pressure. (C) Pressure tap location for clutch 1
pressure. (D) Pressure tap location for the clutch 2 pressure. (E) Pressure tap location for the forward low pressure. (F)
Pressure tap location for forward high pressure. (G) Pressure tap location for clutch 3 pressure. (H) Pressure tap location
for the all-wheel drive clutch pressure. (J) Pressure tap location for the reverse clutch pressure.

(A) Pressure tap for pump pressure.

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(B) Pressure tap location for lube pressure. (C) Pressure tap location for clutch 1 pressure.

(D) Pressure tap location for the clutch 2 pressure.

(E) Pressure tap location for Forward Low pressure. (F) Pressure tap location for Forward High pressure.

(G) Pressure tap location for Clutch 3 pressure.

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(H) Pressure tap location for All-wheel drive clutch pressure.

(J) Pressure tap location for reverse clutch pressure.

Visual Checks
For all tests, the engine must be running at LOW idle and the oil must be at normal operating
temperature.

During these checks, use a magnet to separate ferrous particles from nonferrous particles.

1. Check the oil level in the transmission. Look for air (bubbles) or water on the dipstick. Many
problems in the transmission are caused by low oil level or air in the oil. Add oil to the transmission
if it is needed.

a. Air (bubbles) is usually caused by a loose tube or damaged casting that allows air to enter
the suction side of the system along with allowing oil to leak out.

2. Check all oil lines, hoses and connections for leaks and damage. Look for oil on the ground under
the machine.

3. Move the levers for the speed control and the direction control to REVERSE and FORWARD and
all SPEED positions. The detents must be felt in each speed position. The direction control actuation
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 within the transmission oil filter. The oil filter bypass
valve will open and let oil bypass the oil filter element whenever the pressure difference between
inlet oil and outlet oil through the oil filter gets above 138 ± 14 kPa (20 ± 2 psi). Any oil that does
not go through the filter element goes directly into the hydraulic circuit. Dirty oil can cause a
restriction in valve orifices and cause valves to stick.

4. Drain the oil from the transmission case by removing the oil plug and then remove the cover plate
from lower right side of the transmission for further draining of any remaining oil. After removal of
the plate on the lower right side of the transmission case, remove and inspect the suction screen and

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the bottom of the transmission case for debris. Remove and inspect the transmission oil filter for
foreign material.

a. Rubber particles indicate seal or hose failure.


b. Shiny steel particles indicate mechanical failure or gear wear of the transmission or pump.
c. A heavy accumulation of black fiber material indicate worn clutch discs.
d. Aluminum particles indicate a failure of a clutch piston or torque converter.
e. Iron or steel chips indicate broken components in the transmission.

Operational Checks

Make reference to WARNING on the first page of the section


Troubleshooting The Transmission Hydraulic System.

NOTICE

Any unusual noises during this check should be noted. Loud noises
could indicate that repairs are needed.

1. Start the engine.

2. Lower the stabilizers and lift the rear wheels about 150.0 mm (6.0 in.) off the ground.

3. Place the bucket hydraulic controls in the bucket lowering position and lift the front wheels about
150.0 mm (6.0 in.) off the ground.

4. The engine speed is to be at LOW idle.

5. With the engine running and brakes on, move the direction control lever to the forward/reverse
position and the lever for the transmission speeds.

6. Operate the machine in each direction and in all speeds. Make note of noises that are not normal
and find their source. If the operation is not correct, make reference to the Check List During
Operation for "problems" and "probable causes".

Problem: Transmission does not operate in any speed or does not engage (slips) in all speeds.

Probable Cause:

1. Neutral lockout switch engaged.


2. Low oil pressure caused by:

a. Low oil level.


b. Failure of oil pump.
c. Air leaks on inlet side of the pump.

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d. Leakage inside transmission.

3. Mechanical failure in transmission.

a. Clutch discs and plates have too much wear.


b. Leakage at the seals.

4. Electrical failure in shift control unit, ECM or defective transmission control fuse.

Problem: Transmission does not shift to 5th gear forward.

Probable Cause:

1. Speed sensor not adjusted correctly.

Problem: Transmission does not shift.

Probable Cause:

1. Air leaks on inlet side of pump.


2. Wiring to transmission solenoid control valves not connected or broken.
3. Electrical failure in shift control unit, electronic control module or defective transmission
control fuse.
4. Low oil pressure - see Oil Pressure Too Low, Probable Cause.

Problem: Transmission gets hot.

Probable Cause:

1. Bad temperature gauge.


2. High oil level.
3. Core of oil cooler not completely open.
4. Too much slipping in the clutch.

a. Low oil pressure - see Oil Pressure Too Low, Probable Cause.
b. Damaged clutch.

5. Bypass valve in the thermostat stuck in the open position.


6. Low oil flow as a result of pump wear or extra leakage in the hydraulic system.
7. Wrong application for vehicle. Too much torque converter slippage caused by too much
load.
8. Air in the oil. Air leaks on intake side of pump.
9. Low oil flow through torque converter, caused by torque converter relief valve being stuck
open.
10. Wrong oil in transmission.

Problem: Pump noise not normal.

Probable Cause:

1. A loud sound at short time periods gives an indication that foreign material is in the
transmission hydraulic system.
2. A constant loud noise is an indication of pump failure.
3. Failed or damaged suction tube.

Problem: Noise in the transmission which is not normal.

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Probable Cause:

1. Parts have wear or damage.

Problem: Transmission operates in forward speeds only.

Probable Cause:

1. Wiring to transmission reverse solenoid control valve not connected or broken.


2. Shift control unit malfunctioning or defective solenoid.
3. Discs and plates have too much wear in reverse direction clutches.
4. Leakage at seal rings.
5. Reverse clutch components have damage.
6. Control valve gasket has damage.
7. Forward clutch warped.

Problem: Transmission operates in reverse speeds only.

Probable Cause:

1. Wiring to transmission solenoid control valve not connected or broken.


2. Shift control unit malfunctioning or defective solenoid.
3. Discs and plates have too much wear in forward direction clutches.
4. Leakage at the seal rings.
5. Forward clutch components have damage.
6. Control valve gasket has damage.
7. Reverse clutch warped.

Problem: Clutch engagement is slow and makes rough shifts.

Probable Cause:

1. Low transmission oil pressure - see Oil Pressure Too Low, Probable Cause.
2. Internal (inner) oil leaks.
3. Sticking solenoids.

Problem 1: Oil pressure too low.

Probable Cause:

a. Low oil level.


b. Failure of transmission oil pump.
c. Suction leak.
d. Wrong oil in transmission.

Troubleshooting Methods
Electrical Testing

Electrical connections between harnesses may not be tight. This can cause electrical problems, either
permanent or intermittent (come and go). Ensure that the connections at the speed solenoids, the
forward high solenoid, forward low solenoid, reverse solenoid, all-wheel drive solenoid and the all-
wheel drive switch are tight before other tests are made.

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6V-7070 Digital Multimeter

Use the 6V-7070 Digital Multimeter or equivalent for making continuity checks, resistance
measurements or voltage measurements. The optional 8T-3224 Needle Tip Group for the 6V-7070,
is useful during troubleshooting. For instruction on use of the 6V-7070, see Special Instruction
SEHS7734.

NOTE: Except for harness tests, continuity testers (such as 8T-0500), or voltage testers (such as 5P-
7277) are not recommended for use on present-day Caterpillar electrical circuits.

Transmission Hydraulic System Tests

Make reference to WARNING on the first page of the section


Troubleshooting The Transmission Hydraulic System.

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NOTICE

For all tests, the machine must be at operating temperature.

Remove the floor mat, floor plate and access plate.

Proceed to the appropriate test required. When testing is completed re-install the floor plates, access
plate and floor mat to the cab.

Test 1.
Transmission Oil Pump Pressure

This test will show if:.

a. Transmission oil pump is good.

Procedure:

1. At pressure tap (A), use a coupler and connect a pressure gauge [4000 kPa (600 psi)] to the
nipple.

2. Place the direction conrtol lever in the NEUTRAL position.

3. With the parking brake engaged, start and run the engine at LOW IDLE rpm.

4. Shift the direction control lever into the FORWARD position and with the speed shift lever in
NEUTRAL, run the engine at HIGH IDLE rpm. The pressure on the gauge must be 1450 ± 100 kPa
(210 ± 15 psi).

5. When this test is complete, reduce engine speed to LOW IDLE, place direction control lever in
NEUTRAL, stop engine and remove the test equipment.

Test 2.
Torque Converter Stall

This test will show if:

a. Engine performance is good.


b. Torque converter operates correctly.
c. There is oil flow through oil cooler.

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NOTICE

Any unusual noises during this check should be noted. Loud noises
could indicate that repairs are needed.

1. Start the engine.

2. The engine speed is to be at LOW.

3. Lower the stabilizers and lift the rear wheels about 150.0 mm (6.0 in.) off the ground.

4. Place the bucket hydraulic controls in the bucket lowering position and lift the front wheels about
150.0 mm (6.0 in.) off the ground.

5. Stop the engine, and proceed with the following procedure.

Procedure:

1. Install the 6V-3121 Multitach Group on the engine. The 6V-3121 Multitach Group can measure
engine rpm by the use of the photo pickup and reflective tape. Special Instruction Form No.
SEHS7807 has instructions for its use.

2. With the transmission shift lever in NEUTRAL position, start and run the engine at LOW IDLE
rpm. Ensure that HIGH IDLE rpm and LOW IDLE rpm are correct according to the specifications in
the book titled "3054 Engine for Caterpillar Built Machines", Form SENR5815.

NOTICE

To make sure that the transmission oil does not get hot, do not hold the
transmission in a stall condition for more than ten seconds. After the
transmission is stalled, put the controls in NEUTRAL and run the
engine at 1200 to 1500 rpm to cool the oil.

3. With engine running at HIGH IDLE rpm, brakes fully engaged and the transmission at normal
operating temperature [59 to 71°C (138 to 160°F)], shift to FOURTH SPEED position. Shift the
direction control lever to FORWARD and stall the torque converter until converter temperature
reaches 90 to 93°C (194 to 200°F). With these conditions, stall rpm should be as per Stall RPM
Chart.

NOTE: The following torque converter stall rpm chart is based on using field fuel (#2 Diesel Fuel).
Factory fuel may cause the rpm to be lower than what is indicated in the chart.

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4. When the test is complete, place the direction control lever into NEUTRAL. Stop the engine and
remove test equipment.

NOTICE

Do not keep the torque converter in a stall condition for very long
periods of time. This will cause the torque converter, engine and
brakes to get hot.

Problem 1: The oil gets too hot during normal operation.

Probable Cause:

a. Not enough oil in torque converter because torque converter inlet relief valve is open.
b. Failure in oil pump.
c. Failure in torque converter.
d. Bad temperature gauge. Replace temperature gauge and the sending unit.
e. Debris blocking air flow to oil cooler and/or engine cooler.

Problem 2: High idle is correct, but stall speed (rpm) is too high.

Probable Cause:

a. Bad torque converter.

Problem 3: Stall speed (rpm) is low.

a. Engine problem.
b. Factory fuel
c. Torque converter problem.
d. Transducer.

Test 3.
Forward High, Forward Low, Clutch 1, Clutch 2, Clutch 3, Reverse Clutch
Pressure And Transmission Lubrication

This test will show if:

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a. Oil pressure to the forward high clutch, forward low clutch clutch 1, clutch 2, clutch 3 and
reverse clutch is good.
b. Oil pressure to the transmission lubrication circuit is good.

Procedure:

1. Install the 6V-3121 Multitach Group on the engine. The 6V-3121 Multitach Group can measure
engine speed (rpm) by the use of the photo pickup and reflective tape. Special Instruction Form No.
SEHS7807 has instructions for it use.

2. At pressure taps (B), (F), (G) and (J) connect a hose group to the nipple assemblies.

(F) Pressure tap location for Forward High clutch.

(E) Pressure tap location for Forward LOW clutch.

(J) Pressure tap location for Reverse clutch.

(C) Pressure tap location for Clutch 1.

(D) Pressure tap location for Clutch 2.

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(G) Pressure tap location for Clutch 3.

(B) Pressure tap for lubrication and cooling.

3. At pressure tap (F), (E), (C), (D), (G) AND (J) connect a pressure gauge [4000 kPa (600 psi)] to
the hose group.

4. At pressure tap (B) connect a pressure gauge [400 kPa (60 psi)] to the hose group.

5. Start and run the engine at LOW IDLE speed.

6. With the transmission gear shift lever in NEUTRAL, shift the direction control lever to 1st speed
FORWARD. The pressure on the forward low clutch gauge must be 1325 ± 225 kPa (190 ± 30 psi).
The pressure on the clutch 1 gauge must be 1375 ± 225 kPa (200 ± 30 psi). The lubrication gauge
must be 50 ± 25 kPa (10 ± 5 psi).

7. Shift the direction control lever to 2nd speed forward. The pressure on the forward high clutch
must be 1325 ± 225 kPa (205 ± 30 psi). The pressure on the clutch 1 gauge must be 1375 ± 225 kPa
(200 ± 30 psi).

8. Shift the direction control lever to 3rd speed forward. The pressure on the forward low clutch
must be 1325 ± 225 kPa (205 ± 30 psi). The pressure on the clutch 2 gauge must be 1475 ± 225 kPa
(215 ± 30 psi).

9. Now shift the direction control lever to 3rd speed REVERSE. The reverse clutch pressure must be
1325 ± 225 kPa (190 ± 30 psi). The pressure on the clutch 3 gauge must be 1475 ± 225 kPa (215 ±
30 psi).

10. When the test is complete, move the direction control lever into NEUTRAL, engage the parking
brakes and stop the engine. Remove test equipment.

Problem 1: Both forward high, and forward low clutch pressure too low.

Probable Cause:

a. System relief valve spring weak.


b. Oil level low.
c. Oil filter is plugged. Replace dirty oil filter.
d. Oil pump failure.
e. Neutralizer button on gear shift lever or tilt control lever shorted causing transmission
control solenoid valve to de-energize.
f. Clutch piston seals bad.

Problem 2: Reverse clutch, clutch 1, clutch 2, or clutch 3 pressure too low.

Probable Cause:

a. Faulty solenoid.
b. Clutch piston seals bad.
c. Faulty or missing seals on input shaft.

Troubleshooting The All-Wheel Drive System

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To prevent possible injury, do the procedure that follows before testing


and adjusting the differential, rear axle and brakes:

1. Move the machine to a smooth horizontal location. Move away from working machines and
personnel. Stop the backhoe loader engine.

2. Permit only one operator on the machine. Keep all other personnel either away from the machine
or in view of the operator.

3. Activate the parking brakes. Lower the buckets or implements (loader and backhoe) and
stabilizers to the ground.

Visual Checks
Before any operational checks are made to the all-wheel drive, visually inspect all components.

1. Check the electrical connections.

2. Check for oil leaks around the all-wheel drive solenoid and front drive output shaft, the
differential and the wheel planetary assemblies.

Operation Checks
An operational check can be made to quickly see if the all-wheel drive is functional.

NOTICE

Any unusual noises during this check should be noted. Loud noises
could indicate that repairs are needed.

1. Start the engine.

2. Lower the stabilizers and lift the rear wheels about 150.0 mm (6.0 in.) off the ground.

3. Place the bucket hydraulic controls in the bucket lowering position and lift the front wheels about
150.0 mm (6.0 in.) off the ground.

4. The engine speed is to be at LOW idle.

5. Shift the directional control lever to the FORWARD position.

6. Shift the transmission to first speed and note if a rear wheel or wheels rotate.

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7. Activate the all-wheel drive switch and note if a front wheel or wheels rotate. If the front wheel or
wheels rotate, the all-wheel drive is operational. If there is no front wheel rotation, troubleshoot the
system.

8. If the wheels do not rotate, check for the obvious reasons.

a. Malfunctioning electrical connections.


b. Broken axle shaft.
c. Damaged or broken transfer driveshaft.
d. All-wheel drive solenoid is malfunctioning, or is defective.

9. If the wheels do not disengage, check for possibility of:

a. Electrical problem.
b. Warped or damaged clutch
c. All-wheel drive solenoid is malfunctioning, or is defective.

Troubleshooting Methods
Electrical Testing

Electrical connections between harnesses may not be tight. This can cause electrical problems, either
permanent or intermittent (come and go). Ensure that the connections at the all-wheel drive solenoid
and the all-wheel drive switch are tight before other tests are made.

6V-7070 Digital Multimeter

Use the 6V-7070 Digital Multimeter or equivalent for making continuity checks, resistance
measurements or voltage measurements. The optional 8T-3224 Needle Tip Group for the 6V-7070,
is useful during troubleshooting. For instruction on use of the 6V-7070, see Special Instruction
SEHS7734.

NOTE: Except for harness tests, continuity testers (such as 8T-0500), or voltage testers (such as 5P-
7277) are not recommended for use on present-day Caterpillar electrical circuits.

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Pressure Testing

The transmission case contains a clutch pack for all-wheel drive engagement. The pressure needed
for proper clutch engagement is 1575 ± 225 kPa (230 ± 30 psi).

Test Procedure

1. Remove plug (H) from transmission and install a test nipple.

2. Install a 0 to 4000 kPa (0 to 600 psi) gauge and long hose.

3. Start the engine and run at high idle speed.

4. At normal operating temperature and with the gear shift selector in the NEUTRAL position, place
the direction control lever in the FORWARD position.

5. Activate the all-wheel drive solenoid.

6. Read pressure at the pressure gauge. If the oil pressure is not 1575 ± 225 kPa (230 ± 30 psi), refer
to the Transmission Hydraulic System Tests.

Copyright 1993 - 2020 Caterpillar Inc. Fri Aug 21 20:15:35 EST 2020
Todos los derechos reservados.
Red privada para licenciados del SIS.

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