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Pruebas y Ajustes
R1600G LOAD HAUL DUMP POWER TRAIN
Número de medio -RENR7832-00 Fecha de publicación -01/11/2003 Fecha de actualización -23/03/2004
RENR78320002
Troubleshooting
Machine Preparation for Troubleshooting
SMCS Code: 3000-035
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the attachments have been lowered, and the oil is cool
before removing any components or lines. Remove the oil filler cap only
when the engine is stopped, and the filler cap is cool enough to touch
with your bare hand.
Personal injury or death can result from escaping fluid under pressure.
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Escaping fluid under pressure, even a very small pin-hole size leak, can
penetrate body tissue and cause serious injury and possible death. If
fluid is injected into your skin, it must be treated immediately by a
doctor familiar with this type of injury.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the machine. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
NOTE: Permit only one operator on the machine. Keep all other personnel away from the machine
or in the operator's sight.
1. Move the machine to a smooth, horizontal location that is away from operating machines and
away from personnel.
2. Place the transmission direction and speed control in the NEUTRAL position and in any speed
position. Engage the steering and transmission lock lever.
3. Engage the parking brake. Place wheel locks in front of the wheels and behind the wheels.
4. When the work tool is raised for testing or for adjusting, make sure that the work tool is supported
correctly. Also, make sure that the work tool is fully in the DUMP position. The lift circuit has high
oil pressure when the lift circuit has high oil pressure when the lift arms raise the front of the
machine.
NOTE: Do not stop the machine with the front of the machine off the ground unless this is required
for a test. Lower the machine to the ground and stop the engine.
7. Move the joystick control lever through the full range of travel. This will relieve any pressure that
may be present in the implement hydraulic system.
8. Move the steering control several times in both directions to release the pressure in the steering
system.
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Reference: Refer to Systems Operation, Testing & Adjusting, Braking System, "System Pressure -
Release" for the machine that is being serviced.
10. Depress the breaker relief valve on the hydraulic tank to release the pressure in the hydraulic
tank.
11. The pressure in the hydraulic system has now been released. Lines and components can be
removed.
NOTE: During a diagnosis of the hydraulic system, remember that correct oil flow and correct
pressure are necessary for correct machine operation. The pump output increases as the engine speed
increases. Furthermore, the pump output decreases. Oil pressure is caused by resistance to the flow
of oil.
Troubleshooting Procedure
When defining a power train problem, the following procedure should be followed. First, perform
Visual Checks. If when complete the problem has not been identified, perform Operational Checks.
If the problem is not fully understood, perform Instrument Tests. This procedure will help identify
power train problems. As soon as the problem is defined, go to Troubleshooting. The
Troubleshooting section will list the probable causes of a known problem. Since there may be more
than one cause for a problem, the Troubleshooting section may suggest specific inspections or
instrument tests be done.
These inspections and tests will help identify which of the causes is most probable. This list cannot
give all possible problems and corrections. The service personnel must find the problem and its
source, then make the necessary repairs.
Visual Inspection
SMCS Code: 3000-035
Turn the battery disconnect switch to the OFF position and remove the
key.
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Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service work is done on the hydraulic system.
Make sure all of the attachments have been lowered, and the oil is cool
before removing any components or lines. Remove the oil filler cap only
when the engine is stopped, and the filler cap is cool enough to touch
with your bare hand.
Personal injury or death can result from Escaping fluid under pressure,
even a very small pin-hole size leak, can penetrate body tissue and cause
serious injury and possible death. If fluid is injected into your skin, it
must be treated immediately by a doctor familiar with this type of
injury.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the machine. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Perform Visual Checks first when troubleshooting a problem. Make the checks with the engine
STOPPED and the parking brake ENGAGED. Put the transmission control in NEUTRAL and
engage the steering and transmission lock lever. During these checks, if necessary, use a magnet to
separate ferrous (iron) particles from nonferrous particles (O-ring seals, aluminium, bronze, etc.).
NOTE: If the machine will not move, check the transmission control circuit breaker on the circuit
breaker panel in the operator's station.
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Check 1:
Check 2:
Check the oil level in the transmission. Look for air or water in the oil. Many problems in the
transmission are caused by low oil level or air in the oil. Add to the transmission if it is needed.
Reference: For the recommended oil grade and viscosity, refer to Operation and Maintenance
Manual for the machine that is being serviced.
a. Air (bubbles) may be caused by a loose or damaged fitting that allows air to enter the suction side
of the system along with allowing oil to leak out. Air may also be the result of gears agitating oil in
the sump if the transmission oil level is too high (overfill).
b. Coolant in the oil can be caused by a leaking transmission oil cooler. Water may enter the system
if the filler cap or dipstick is not properly installed.
Check 3:
Inspect all oil lines, hoses and connections for damage or leaks. Look for oil on the ground under the
machine.
NOTE: If oil can leak out of a fitting or connection, air can leak in. Air in the system can be as
harmful as not enough oil.
Check 4:
Remove the drain plug in the bottom of the output transfer gear case and the torque converter
updrive housing. This will drain all of the oil out of the transmission system. Remove and clean the
suction screens. Inspect the oil and suction screens for foreign material. Remove and inspect (cup
apart if necessary) the transmission oil filter for foreign material.
NOTE: There is an oil filter bypass valve on the inlet side of the transmission oil filter. The oil filter
bypass will open and let oil bypass the oil filter element whenever the pressure difference between
inlet oil and outlet oil through the oil filter is above 248 ± 21 kPa (36 ± 3 psi). Any oil that does not
flow through the filter element flows directly into the hydraulic control circuit. This dirty oil may
cause restrictions in valve orifices, striking valves, etc.
b. Shiny steel particles indicate mechanical failure or gear wear of the transmission or pump.
c. A heavy accumulation of fibrous material indicates worn clutch discs in the transmission.
d. Aluminum particles indicate torque converter wear or failure, clutch piston wear, or worn control
valve body, selector spools, or load piston in the transmission control valve.
NOTE: If any of the above particles are found during any visual check, all components of the
transmission hydraulic system must be cleaned. Do not use any damaged parts. Any damaged parts
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Check 5:
The drive shaft(s) and universal joints must be free to rotate except when cold oil causes a resistance.
If the shafts are not free to turn, disconnect them and see if the transmission and the torque converter
updrive gears will turn.
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To prevent injury or death, make sure that the area around the
machine is clear of personnel and obstructions before operating the
machine.
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the attachments have been lowered, and the oil is cool
before removing any components or lines. Remove the oil filler cap only
when the engine is stopped, and the filler cap is cool enough to touch
with your bare hand.
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Escaping fluid under pressure, even a very small pin-hole size leak, can
penetrate body tissue and cause serious injury and possible death. If
fluid is injected into your skin, it must be treated immediately by a
doctor familiar with this type of injury.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the machine. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Operational Checks
Operate the machine in each direction and in all speeds. Note the noises that are not normal and find
their source. If the operation is not correct, refer to the following problems and possible causes.
Problem 1:The transmission does not operate in any speed or slips in all speeds.
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Problem 11:Low pressure at pressure taps for P1 (speed) and P2 (direction) clutches in all speeds
and directions.
Problem 14:High pressure at pressure taps for P1 (speeds) and P2 (direction) clutches in all speeds
and directions.
Problem 18:Clutch engagement is slow (slow shifts-all FORWARD or all REVERSE gears or any
one gear in both FORWARD and REVERSE.
Problem 20:Transmission engages but the machine does not move and the engine lugs down.
Problem 21:With the engine running and the parking brake "ENGAGED", the alarm does not sound
when the transmission selection lever is put into either a FORWARD or REVERSE direction.
Problem 22:Backup alarm does not sound when transmission control is put in REVERSE.
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Troubleshooting
NOTE: In the following troubleshooting, the number in parenthesis refer to the transmission
hydraulic schematic.
NOTE: This machine is equipped with an Electronic Transmission Control. Electrical diagnostics
are performed by the Electronic Transmission Control.
Reference: Refer to Systems Operation Troubleshooting, Testing and Adjusting, "Power Train
Electronic Control System" for the machine that is being serviced.
Problem 1: The transmission does not operate in any speed or slips in all speeds.
Possible Causes:
Possible Causes:
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2. Wrong application for the machine. There is too much torque converter slippage caused by too
much load.
8. Low oil flow caused by pump wear or leakage in the hydraulic system.
9. Air mixed in the oil. Air leaks on the intake side of the pump.
11. Torque converter inlet relief valve (12) is stuck open, which causes low oil flow through the
torque converter.
Possible Causes:
1. A loud sound at short time periods indicates that foreign material is in the transmission hydraulic
system.
Possible Causes:
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Possible Causes:
Possible Causes:
Possible Causes:
Possible Causes:
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Possible Causes:
Problem 10: Transmission does not operate in FOURTH SPEED FORWARD or REVERSE.
Possible Causes:
Problem 11: Low pressure at pressure taps for P1 (speed) and P2 (direction) clutches in all
speeds and directions.
Possible Causes:
2. Low oil pressure. See Problem: Transmission does not operate in any speed or slips in all speeds.
Possible Causes:
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Possible Causes:
Problem 14: High pressure at pressure taps for P1 (speed) and P2 (direction) clutches in all
speeds and directions.
Possible Causes:
Possible Causes:
Possible Causes:
Possible Causes:
2. Low oil pressure. See Problem: Transmission does not operate in any speed or slips in all speeds.
Problem 18: Clutch engagement is slow (slow shifts-all FORWARD gears or all REVERSE gears or
any one gear in both FORWARD and REVERSE).
Possible Causes:
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1. Low clutch pressure because of leaking seals on the piston for the affected gear.
Problem 19: Transmission stays engaged when the left brake pedal is pushed.
Possible Causes:
Problem 20: Transmission engages but the machine does not move and the engine lugs down.
Possible Causes:
Problem 21: With the engine running and the parking brake ENGAGED, the action alarm
does not sound when the transmission control is put into either a FORWARD or REVERSE
direction.
Possible Causes:
Problem 22: Backup alarm does not sound when the transmission control is put in REVERSE.
Possible Causes:
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Possible Causes:
2. Cold oil.
Possible Causes:
Possible Causes:
2. There is a clutch failure in the speed or direction that the is high stall speed.
Torque Converter
Possible Causes:
Possible Causes:
2. Low pump flow or pressure. See Problem: Transmission does not operate in any speed or slips in
all speeds.
Possible Causes:
1. Wrong application for the machine. There is too much torque converter slippage caused by too
much load.
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Possible Causes:
Possible Causes:
Possible Causes:
4. The ring gear and pinion do not have correct tooth contact.
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Possible Causes:
Possible Causes:
1. The differential pinion gears are too tight on the retainer pins or the pinion shaft.
Possible Causes:
Possible Causes:
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NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the machine. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
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1. Move the machine to a smooth horizontal location. Move away from working machines and
personnel.
5. Allow only approved personnel on the machine and keep other personnel off the machine and in
clear view of the operator.
NOTE: Make sure the engine is stopped, the parking brake engaged and all hydraulic pressure
released before any fitting, hose or component is loosened, tightened, removed or adjusted.
NOTE: All test and adjustments must be made with the oil in the transmission hydraulic control
system at normal temperature of operation.
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Procedure:
1. Disconnect J-1 (3) and J-2 (2) cab harness plugs from the Power Train ECM (1). Put a jumper
wire from Socket 1 of J-1 harness plug (3) to Socket 13 of J-2 harness plug (2). This will supply + 24
Volts through the machine harness to actuate the lockup solenoid.
3. Turn the key start switch to the ON position but do not start the engine.
4. Touch the lockup solenoid plug to the harness receptacle at connector (4).
5. Each time the receptacle touches the solenoid plug a "click" and/or "buzz" must be felt and/or
heard.
Problem 1:
Possible Cause:
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Procedure:
1. At pressure tap (B) (port marked [RV]), remove the plug and install a nipple.
2. With a coupler (and hose if necessary), connect a pressure gauge [4000 kPa (580 psi)] to the
nipple.
3. With the parking brake engaged, start and run the engine at LOW IDLE rpm in NEUTRAL. The
pressure on the gauge must be 1725 ± 100 kPa (250 ± 15 psi).
4. Stop the engine. After the pressure is set correctly, remove the test equipment.
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Before an adjustment is made, make sure that the valve spring is not weak or broken.
Problem 1:
Probable Cause:
Shim adjustment incorrect. Add some shims (6). See Shim Chart for Pressure Reduction Valve.
Problem 2:
Probable Cause:
Shim adjustment incorrect. Remove some shims (6). See Shim Chart for Pressure Reduction Valve.
Procedure:
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3. Measure the amount of oil that comes out of pressure tap (C) in one minute. Install the protective
cover on the test nipple when this check is complete.
Problem 1:
More than 3.8 L/min (1 U.S. gpm) of oil comes out of pressure tap (C).
Probable Cause:
Procedure:
2. Using a 2-pin sure seal connector, two alligator clips and two 16-gauge wires [approximately 4.5
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m (15 ft) long], make a jumper harness. Connect the clip ends of the jumper harness to the positive
(+) and negative (-) terminals of the machine battery. This will supply +24 Volts to activate the
lockup solenoid.
3. At pressure tap (C), use a coupler (and hose if necessary) and connect a pressure gauge [4000 kPa
(580 psi)] to the nipple.
4. With the parking brake engaged, start and run the engine at LOW IDLE rpm in NEUTRAL.
Connect the connector end of the jumper harness to the connector of the lockup solenoid. The
pressure on the gauge must be 1690 ± 70 kPa (245 ± 10 psi).
5. Remove the jumper harness connector from the lockup solenoid. The pressure on the gauge must
go back to 0 kPa (0 psi).
6. Stop the engine. After the pressure is set correctly, remove the test equipment.
(8) Cover.
(9) Selector piston.
(10) Load piston ring.
(11) Shims.
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Problem 1:
Probable Cause:
a. Selector piston (9) is stuck (will not go back to its original position).
Problem 2:
Probable Cause:
Problem 3:
Oil pressure in Step 4 does not increase above 965 kPa (140 psi).
Probable Cause:
Problem 4:
Oil pressure in Step 5 decreases slowly or low pressure remains (stays) in the lockup clutch.
Probable Cause:
Problem 5:
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Probable Cause:
Problem 6:
Probable Cause:
Procedure:
2. Using a 2-pin sure seal connector, two alligator clips and 16-gauge wires [approximately 4.5 m
(15 ft) long], make a jumper harness. Connect the clip ends of the jumper harness to the positive (+)
and negative (-) terminals of the machine battery. This will supply +24 Volts to activate the lockup
solenoid.
3. At pressure tap (C), use a coupler (and hose if necessary) and connect a pressure gauge [2000 kPa
(290 psi)] to the nipple.
4. Remove cover (8) from the lockup clutch and solenoid valve group.
5. Remove load piston plug (10) and install cover (8) again.
6. With the parking brake engaged, start and run the engine at LOW IDLE rpm in NEUTRAL.
Connect the connector end of the jumper harness to the connector of the lockup solenoid. The
pressure on the gauge must be 620 ± 35 kPa (90 ± 5 psi).
7. Stop the engine. After the pressure is set correctly, remove the test equipment and reinstall load
piston plug (10).
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Before an adjustment is made, make sure that the valve spring is not weak or broken.
(8) Cover.
(9) Selector piston.
(10) Load piston plug.
(11) Shims.
(12) Outer spring.
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Problem 1:
Probable Cause:
Problem 2:
Probable Cause:
Shim adjustment incorrect. Add some shims (11). See Shim Chart for Modulation Reduction Valve.
Problem 3:
Probable Cause:
Shim adjustment incorrect. Remove some shims (11). See Shim Chart for Modulation Reduction
Valve.
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1. Move the machine to a smooth horizontal location. Move away from working machines and
personnel.
5. Allow only approved personnel on the machine and keep other personnel off the machine and in
clear view of the operator.
NOTE: Make sure the engine is stopped, the parking brake engaged and all hydraulic pressure
released before any fitting, hose or component is loosened, tightened, removed or adjusted.
NOTE: All tests and adjustments must be made with the oil in the transmission hydraulic control
system at normal temperature of operation.
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After the NoSPIN differential has been assembled and before it is installed in the machine, make a
test of the operation of the differential as follows:
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(1) Case.
(2) Axle.
(3) Axle.
5. Keep the force on axle (A) and turn axle (B) in a counterclockwise direction. A small noise will be
heard in the NoSPIN differential and axle (B) will turn freely.
6. Keep the force on axle (A) and turn axle (B) in a clockwise direction. A small noise will be heard
in the NoSPIN differential and axle (B) will not turn any further.
8. Keep the force on axle (A) and turn axle (B) in a clockwise direction. A small noise will be heard
in the NoSPIN differential and axle (B) will turn freely.
9. Keep the force on axle (A) and turn axle (B) in a clockwise direction. A small noise will be heard
in the NoSPIN differentiae and axle (B) will not turn any farther.
10. Perform Steps 4 through 9 again, except now hold axle (B) and turn axle (A).
If the NoSPIN differential does not have the correct action, inspect the components and check the
assembly procedure.
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