R1600 LHD

CATERPILLAR ELPHINSTONE PTY. LTD.

Ser
vice T
raining Guides
Service
Training

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POWER TRAIN

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Contents
Introduction .................................................................3
Power Train Component Location ...............................4
Torque Converter ........................................................5

Help

Torque Converter (Converter Drive) ............................6

Torque Converter (Direct Drive) ..................................7

Index

Torque Converter Hydraulic System Schematic .........8

Lockup Clutch Valve (Torque Converter Drive) ...........9
Lockup Clutch Valve (Clutch Filling) ..........................10
Lockup Clutch Valve (Direct Drive) ............................11
Torque converter Updrive Transfer Gears ................. 12
Transmission Oil Flow ...............................................13
Transmission Oil Pump .............................................14
Torque Converter Scavenge Pump ........................... 15
Solenoid Valves .........................................................16
Transmission Hydraulic Control Group...................... 17
Transmission Hydraulic System Operation (Neutral) 18
Transmission Hydraulic System Operation (First Speed Forward) ........................................................ 19
Transmission Pressure Tap Location......................... 20
Planetary Transmission .............................................21
Output Transfer Gears ...............................................22
Axle Group ................................................................23
Autoshift Transmission Electronic Control System ....24
Transmission Electronic Control Module ...................25

Input Components .....................................................26

Input Components .....................................................27
Sensor and Switch Inputs .........................................28
Output Components ..................................................29
Diagnostic Operation .................................................30
Find System Faults (Practical Task) ..........................31

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Introduction:

Menu

Schematic colour
code:

Help

Testing &
Adjusting
procedures:

Index

Servicemans
Handouts:

Introduction
The colour codes for hydraulic oil used throughout this presentation are as follows:
Red - System or high pressure.
Red and White Stripes - Reduced pressure.
Orange - Torque converter inlet pressure.
Brown - Lubrication or cooling oil.
Green - Tank or return oil

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Menu
Help
Index

(11

10

11

12

13

14

Power 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 Train
Components:

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The torque
converter provides
a fluid coupling in
torque converter
drive
- Speeds N, 1st
forward

Menu
Help
Index

1
1. Torque converter.

2. Torque converter outlet relief valve.

The torque
converter provides
a mechanical
coupling in direct
drive
- Speeds 2 to 4
forward
- Speeds 1 to 4
reverse

3. Converter lock up clutch control valve.

4. Converter scavenge pump.

5. Transmission pump.

Torque Converter

The torque goes to

converter drive
between each shift
(during clutch
engagement) to
provide smooth
shifts

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CATERPILLAR ELPHINSTONE PTY. LTD.

Torque converter
in torque converter
drive

Menu

Oil flows from the

transmission
hydraulic control
to the impeller

Help
Index

The impeller
directs the oil into
the blades of the
turbine and
causes the turbine
to rotate
The turbine and
output shaft rotate
slower than the
engine and
impeller, but with
increased torque

Torque Converter (Converter Drive)

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Torque converter
in direct drive

Menu

The lockup clutch

is engaged and
locks the turbine
to the impeller

Help
Index

The housing,
impeller, turbine
and output shaft
rotate as a unit at
engine rpm

Torque Converter (Direct Drive)

,,
,,

Speed Clutch Oil

Exit

Converter Inlet Oil

,,,
,,,

Converter Outlet Oil

Lubrication Oil

Menu

Tank Oil

Help
2

Index
4

,,
,,

CATERPILLAR ELPHINSTONE PTY. LTD.

,,,,,
,,,,,
,,,,,
,,,,,
,,
,,,,,
,,
,,,,,,,
,,
,,,,,,,
,,,
,,
,,,,,,,
,,,

7
8

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 output
transfer gearcase
is the reservoir for
the transmission
oil system
The transmission
hydraulic control
valve divides
pump flow
between the
torque converter
and transmission
hydraulic systems

LOCKUP CLUTCH VALVE

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TORQUE CONVERTER DRIVE

LOAD
PISTON

CATERPILLAR ELPHINSTONE PTY. LTD.

Lockup clutch and

solenoid valve in
torque converter
drive

SELECTOR
PISTON

Help
Index

MODULATION
REDUCTION
VALVE

LOAD PISTON
ORIFICE

LOCKUP
SOLENOID

PRESSURE
REDUCTION
VALVE

Supply oil from the

transmission
pump is used to
provide lockup
clutch oil
This supply
pressure is
reduced to provide
pilot pressure to
the solenoid valve

When the solenoid

is energized,
TO
SHUTTLE
FROM
supply pressure is
LOCKUP
VALVE
TRANSMISSION reduced by the
CLUTCH
PUMP
modulation
reduction valve to
Lockup Clutch Valve (Torque Converter Drive)
In this illustration and those that follow, the colours used to identify the various pressures in the provide lockup
clutch pressure
systems are as follows:
Red - Supply oil pressure
Green - Drain or tank oil
Red and White Stripes - Lockup clutch pressure
Brown - Lubrication or cooling pressure
Orange - Pilot or torque converter pressure
Yellow - Moving components

LOCKUP CLUTCH VALVE

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Menu

CLUTCH FILLING
LOAD
PISTON

CATERPILLAR ELPHINSTONE PTY. LTD.

Lockup solenoid
energized

SELECTOR
PISTON

Help
Index

MODULATION
REDUCTION
VALVE

LOAD PISTON
ORIFICE
PRESSURE
REDUCTION
VALVE

LOCKUP
SOLENOID

ON

SHUTTLE
VALVE

TO
LOCKUP CLUTCH

Lockup Clutch Valve (Clutch Filling)

The lockup
solenoid valve
directs pilot
pressure to move
the selector piston
and load piston
down

The load piston

springs move the
modulation
reduction valve
spool down. This
movement opens
the supply
passage from the
FROM
transmission
TRANSMISSION pump and permits
PUMP
pressure oil to
flow to the lockup
clutch

LOCKUP CLUTCH VALVE

DIRECT DRIVE

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Menu

LOAD
PISTON

CATERPILLAR ELPHINSTONE PTY. LTD.

Lockup clutch at
maximum
pressure

SELECTOR
PISTON

Help
Index

MODULATION
REDUCTION
VALVE

LOAD PISTON
ORIFICE
PRESSURE
REDUCTION
VALVE

LOCKUP
SOLENOID

ON

SHUTTLE
VALVE

TO
LOCKUP
CLUTCH

Lockup Clutch Valve (Direct Drive)

FROM
TRANSMISSION
PUMP

The modulation
reduction valve
causes the
maximum
pressure setting of
the clutch to be
lower then the
transmission
supply oil
pressure

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CATERPILLAR ELPHINSTONE PTY. LTD.

Menu
4

Help
Index

3
1

2
2
4

Torque Converter Updrive Transfer Gears

(1) Drive from

engine flywheel
(2) Torque
converter
output shaft
(3) Drive for the
implement,
steering and
pilot pumps
(4) Drive for the
torque
converter
scavenge and
transmission
pumps
(5) Torque
converter
updrive output

Exit

Menu
Help
Index

,,
,,
,,
,,
,,
,,

,,,
,,,
,,,
,,,
,
,,,,
,,
,
,,
,
11

12

10

CATERPILLAR ELPHINSTONE PTY. LTD.

Components

,,,,,
,,,,,

13

Transmission Oil Flow

(1) Oil cooler, (2) Torque converter housing,(3) Torque converter,
(4) Updrive transfer gearcase, (5) Lubrication line, (6) Oil pump, (7) Pressure filter,
(8) Control valve, (9) Transmission, (10) Case, (11) Scavenge pump,
(12) Outlet relief valve, (13) Screen magnetic.

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Menu

Help
Index

1. Transmission pump.

2. Transmission oil filter.

3. Magnetic screen.

4. Transmission oil cooler.

Transmission oil
pump
components:
(1) Transmission
oil pump
(2) Transmission
oil filter
(3) Magnetic
screen
(4) Transmission
oil cooler
Transmission oil
pump is the front
section of a
double section
gear type pump
Transmission oil
filter is located
above the updrive
transfer gearcase

Transmission Oil Pump

Transmission oil
cooler uses engine
coolant to cool oil
returning from the
torque converter
to the
transmission

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CATERPILLAR ELPHINSTONE PTY. LTD.

Torque converter
scavenge pump is
the rear section of
the double section
gear type pump
mounted on the
updrive transfer
gearcase

Menu
Help
Index

Oil leakage within

the torque
converter is
returned to the
transmission oil
reservoir by the
scavenge pump

Torque Converter Scavenge Pump

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CATERPILLAR ELPHINSTONE PTY. LTD.

The solenoid
valves are located
in the
transmission
hydraulic controls

Menu
Help

Two position three

way solenoid valve
normally open

Index

Two solenoids
energised:
One speed clutch
One directional
clutch
Chart showing:
Speed
Solenoid
energised
Clutches
engaged

Solenoid Valves
Speed
1-F
2-F
3-F
4-F
N
1-R
2-R
3-R
4-R

Solenoids Energised
2, 6
2, 5
2, 4
2, 3
3
1, 6
1, 5
1, 4
1, 3

Clutches Engaged
2, 6
2, 5
2, 4
2, 3
3
1, 6
1, 5
1, 4
1, 3

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TRANSMISSION
HYDRAULIC CONTROL VALVE

CATERPILLAR ELPHINSTONE PTY. LTD.

MODULATION
RELIEF VALVE

Menu
Help
CONVERTER INLET
RATIO VALVE

Index
DIRECTIONAL
SELECTOR
SPOOL
PRESSURE
DIFFERENTIAL
VALVE

,,,
,,,
,,,

SECOND AND FOURTH

SPEED SELECTOR SPOOL

LOAD PISTON

FIRST AND THIRD SPEED

SELECTOR SPOOL

Transmission Hydraulic Control Group

Located on top of
the transmission
planetary group
Regulate and
control the oil
supply to the
torque converter,
transmission
clutches and
lubrication circuit

TRANSMISSION HYDRAULIC SYSTEM

3

Exit

NEUTRAL

Menu
6

Help

E
C

Index
D

,,,,
,,,,
,,,,
2

3
5

CATERPILLAR ELPHINSTONE PTY. LTD.

Transmission
hydraulic system,
transmission in
neutral
ECM energizes the
No.3 solenoid. Oil
flow from the
solenoid valve
moves the selector
spool. Oil from
the selector and
pressure control
valve flows
through the orifice
to the No.3 speed
clutch

Transmission Hydraulic System Operation (Neutral)

In neutral the
forward and
reverse solenoids
are not energized.
Oil flow to the
directional
clutches is
blocked

TRANSMISSION HYDRAULIC SYSTEM

FIRST SPEED FORWARD

2

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Menu
6

Help

E
C

Index

,,,,
,,,,
,,,,
,,,,

D
3

Transmission Hydraulic System Operation (First Speed Forward)

Transmission
hydraulic system,
transmission in
first speed forward
Electronic
transmission
control module
energizes clutch
solenoids No.2
and No.6. Oil from
solenoid valve
No.2 moves the
directional clutch
selector spool (F).
Directional clutch
oil flows from the
selector spool into
the forward
directional clutch
Oil from solenoid
valve No.6 moves
selector spool (G)
and sends oil
through the orifice
to clutches No.4
and No.6

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CATERPILLAR ELPHINSTONE PTY. LTD.

Transmission
pressure tap
location
(1) (P1) - Speed
clutch
(2) (P2) - Direction
clutch
(3) (P3) - Torque
converter inlet
(4) (P4) - Plug for
the load piston
(LP)

Menu
Help

Index

Transmission Pressure Tap Location

Always refer to the Service Manual for the correct adjusting procedure and specifications.

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CATERPILLAR ELPHINSTONE PTY. LTD.

The transmission
has six clutches
that give four
forward and four
reverse speeds

Menu
Help

The transmission
has two directional
clutches and four
speed clutches

Index

One directional
clutch and one
speed clutch must
engage to transmit
power through the
transmission

Planetary Transmission
Transmission Selection
Neutral
First Speed Forward
Second Speed Forward
Third Speed Forward
Fourth Speed Forward
First Speed Reverse
Second Speed Reverse
Third Speed Reverse
Fourth Speed Reverse

Clutches Engaged in Transmission

3
2 and 6
2 and 5
2 and 4
2 and 3
1 and 6
1 and 5
1 and 4
1 and 3

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Menu
3
2

Help
Index

Output Transfer Gears

(1) Drive gear, (2) Driven gear, (3) Shaft, (4) Yoke assembly front, (5) Yoke assembly rear.

Output transfer
gear components:
Lubrication is
provided by splash
feed from return
oil in the bottom of
the case

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CATERPILLAR ELPHINSTONE PTY. LTD.

4
The differential
sends the same
amount of torque
to each wheel

Menu
Help

The final drives

cause the last
speed reduction
and torque
increase in the
drivetrain

Index

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.

Exit
Menu
Help
Index

TRANSMISSION
ELECTRONIC
CONTROLLER

STIC
CONTROLLER

CATERPILLAR ELPHINSTONE PTY. LTD.

Transmission
Electronic Control
System:

START
RELAY
ENGINE SPEED
SENDER
TRANSMISSION
SPEED SENSOR

BACKUP
ALARM

AUTO/MANUAL
SHIFT SWITCH

TRANSMISSION
CONTROL
SOLENOIDS

RIDE CONTROL
SWITCH
REMOTE
CONTROL
SWITCH

1st GEAR 2nd GEAR 3rd GEAR 4th GEAR

PARKING BRAKE
PRESSURE SWITCH
STEERING LOCK
SWITCH
OPTION CODE
CONNECTOR
KEY START
SWITCH
TRANSMISSION
NEUTRALISER SWITCH

TRANSMISSION
CONTROL
SOLENOIDS
FORWARD REVERSE
RIDE
CONTROL
SOLENOID
LOCKUP
CLUTCH
SOLENOID
CAT DATA LINK

Autoshift Transmission Electronic Control System

- Inputs to the
transmission
electronic control
are shown on the
left hand side of
the diagram
- Outputs from the
transmission
electronic control
are shown on the
right hand side of
the
diagram
The transmission
electronic control
is the heart of the
transmission
electrical system
The control
receives various
inputs and sends a
response through
an output

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CATERPILLAR ELPHINSTONE PTY. LTD.

The Transmission
Electronic Control
is connected to
the Caterpillar
Monitoring System
through the Cat
Data Link

Menu
Help
Index

Fault information
can be read on the
Monitoring System
panel or through
the Electronic
Technician (ET)
The transmission
control has two
types of inputs:
- Switch type
- Sensor type

Transmission Electronic Control Module

The data link

allows the
transmission
control to receive
and send
information to the
Caterpillar
Monitoring System

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Menu

CATERPILLAR ELPHINSTONE PTY. LTD.

3
1

Help
Index

STIC Controller.

4. Steering lock lever.

5. Component location.

Input Components

There are three

switches on the
STIC controller:
(1) Direction
switch
(2) Upshift switch
(3) Downshift
switch
When the
transmission is in
the MANUAL
mode, the
transmission
shifts to the exact
gear and direction
selected by the
operator
When the
transmission is in
the AUTO mode,
the transmission
automatically
shifts based on
engine and
transmission
output speeds

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CATERPILLAR ELPHINSTONE PTY. LTD.

Menu
Help
Index

1. Key start switch.

2. Auto/manual transmission switch.

If the shift switch

is in NEUTRAL, the
control sends
power to the start
relay to start the
engine

3
4

3. Remote control switch.

The key start

switch sends a
signal to the
transmission
control when the
switch is turned to
the START
position

4. Ride control switch.

The auto/manual
switch selects
either automatic or
manual
transmission
shifting

Input Components
In MANUAL mode,
the transmission
will shift to the
speed and
direction selected
by the operator

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CATERPILLAR ELPHINSTONE PTY. LTD.

The transmission
control uses
engine speed to
set automatic shift
points

Menu
Help
Index

2. Transmission speed sensor.

1. Engine speed sensor.

3
3. Park brake pressure switch.
4. Park brake pressure switch.

5. Transmission neutraliser switch.

Sensor and Switch Inputs

The control sends

engine speed
information to the
Caterpillar
Monitoring System
over the data link
The transmission
control uses
transmission
speed to set
automatic shift
points and control
ride control
activation
The transmission
control sends
transmission
speed information
to the Caterpillar
Monitoring System
over the data link

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CATERPILLAR ELPHINSTONE PTY. LTD.

1
Menu

Help
Index

1. Transmission control solenoids.

2. Converter lock up clutch solenoid.

3. Ride control solenoid.

5
4

4. Start relay.

4. Back up alarm.

Output Components

The transmission
control activates
the transmission
solenoid valves to
direct pilot oil to
the ends of the
control spool - the
control spool
shifts to direct
pressure oil to the
transmission
clutches
The transmission
control activates
the torque
converter lockup
clutch which
engages direct
drive
The transmission
control energises
and de-energises
the ride control
solenoid based on
inputs to the
control

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CATERPILLAR ELPHINSTONE PTY. LTD.

The transmission
electronic control
detects faults that
occur in most
input and output
circuits

Menu
Help

The control stores

the fault
information for
future reference

Index

The service code

consists of an MID,
a CID and an FMI
The Module
Identifier (MID)
tells which
electronic control
diagnosed the
fault

Diagnostic Operation
If the Caterpillar
Monitoring System
shows a number
other than 081
during diagnosis,
the fault is not
related to the
transmission
system

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CATERPILLAR ELPHINSTONE PTY. LTD.

Explain tasks:

Menu

Service Manual:

Help
Index

Find System Faults (Practical Task)

Each trainee will be required to successfully complete the tasks listed below.
1. Connect the diagnostic scroll box (service box) or a PC with the ET program to access the
diagnostic function of the transmission electronic control.
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.