Transmision Direct Drive Assemble 416 PDF

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
Configuración: 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)
Número de medio -RENR3574-05 Fecha de publicación -01/10/2005 Fecha de actualización -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 g01211109
(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. Wed May 18 21:14:33 UTC-0400 2011
Todos los derechos reservados.
Red privada para licenciados del SIS.
416D Backhoe Loader B2D00001-UP (MACHINE) POWERED BY 3054C Engine(SEBP4184 - 22) - Estructura del producto
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BY 3054C Engine
Desarmado y Armado
416D, 420D, 424D, 428D, 430D, 432D, 438D and 442D Backhoe Loaders Power Train
i01381641
Transmission (Direct Drive) - Assemble

SMCS - 3030-016-DD; 3066-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 137-8102 Spring Compressor 1
B 1P-1859 Snap Ring Pliers 1
C 4C-3652 Spring Compressor 1
D 6V-2157 Link Bracket 1
E 8T-5096 Indicator 1
F 1U-5750 Engine Stand 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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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
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.
2. Install the seals on piston (56) .
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) .
4. Install clutch pack (53) and retainer (52) .
5. Repeat Steps 2 through 4 for the opposite end of the input shaft.
6. Install gear (51), needle bearing (50), and spacer (49). Use tooling (B) in order to install snap ring
(48) .
7. Heat bearing cone (57) to 135 °C (275 °F). Install bearing cone (57) .
8. Install the input shaft.
(Direct Drive) Reverse Shaft
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
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)
1. Install gear (42) .
2. Install housing (41) and gear (40). Use tooling (B) in order to install snap ring (39) .
3. Install synchronizer (38). Install gear (37). Heat bearing cone (36) to 135 °C (275 °F). Install
bearing cone (36) .
4. Install synchronizer (35), spacer (34), and bearings (33) .
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.
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) .
8. Install screws (24) on each of the gearshift rods (23) .
(Direct Drive) Output Shaft (Front)
1. Install seals on piston (22) .
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) .
4. Install clutch pack (18) and retainer (17) .
5. Install thrust washer (16), needle bearing (15), spacer (14), and two roller bearings (13) .
8. Install front output shaft (9) .
Final Assembly
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).
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.
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 .
4. Install yoke (4), washer (5), and bolt (6) .
5. Install plug (3) .
6. Install Implement pump drive shaft (2) in transmission (1) .
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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i01380368
Transmission (Direct Drive) - Disassemble

SMCS - 3030-015-DD; 3066-015
Disassembly Procedure
Table 1
Required Tools
A 1U-5750 Engine Stand 1
B 6V-2157 Link Bracket 1
C 9S-9152 Puller Assembly 1
C 5F-7465 Puller 1
C 3/8inch x 6inch Bolt 2
D 4C-3652 Spring Compressor 1
E 1U-6405 Puller 1
F 4C-3802 Puller 1
G 8H-0663 Puller 1
G 5F-7465 Puller 1
H 8B-7551 Puller 1
H 6V-3010 Puller 1
I 137-8102 Spring Compressor 1
J 4C-3089 Puller 1
K 1P-1859 Snap Ring Pliers 1
Start By:
A. Remove the transmission. Refer to Disassembly and Assembly, "Transmission (Direct Drive) -
Remove".
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.
1. Install transmission (1) on tooling (A) .
2. Remove Implement pump drive shaft (2) from transmission (1) .
3. Remove plug (3). Drain the transmission oil into a suitable container. The capacity of the
transmission is 11.3 L (3 US gal).
4. Remove bolt (6), washer (5), and yoke (4) .
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)
1. Remove front output shaft (9) .
2. Use tooling (C) in order to remove bearing cone (10) .
3. Use tooling (E) in order to remove bearing cone (11) and gear (12) .
4. Remove two roller bearings (13), spacer (14), needle bearing (15), and thrust washer (16) .
5. Remove retainer (17) and clutch pack (18) .
6. Use a suitable press and tooling (D) in order to compress spring (19). Use tooling (K) in order to
remove snap ring (20) .
7. Remove snap ring (20), retainer (21), and spring (19) .
8. Release piston (22) by blowing shop air into the lube passage, as shown.
9. Use a seal pick in order to remove the seals from piston (22) .
(Direct Drive) Output Shaft (Rear)
1. Remove screws (24) from each of the gearshift rods (23) .
2. Remove plug (25) .
3. Remove plug (25), O-ring (26), two springs (27), and three balls (28). Remove two gearshift rods
(23) from shift forks (29) .
4. Use tooling (E) in order to remove bearing (30), gear (31), and gear (32) .
5. Remove bearings (33), spacer (34), and synchronizer (35) .
6. Use tooling (F) in order to remove bearing (36) and gear (37). Remove synchronizer (38) .
7. Use tooling (K) in order to remove snap ring (39). Remove gear (40) and housing (41) .
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

1. Remove the reverse shaft by hand for disassembly.
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.
2. Use tooling (H) in order to remove bearing (47) .
3. Use tooling (K) in order to remove snap ring (48). Remove spacer (49), needle bearing (50), and
gear (51) .
4. Remove retainer (52) and clutch pack (53) .
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) .
6. Release piston (56) by blowing shop air into the lube passage, as shown.
7. Use a seal pick in order to remove the seals from piston (56) .
8. Use tooling (J) in order to remove bearing (57) and gear (58) .
9. Remove gear (59) from the clutch pack.
10. Repeat Steps 4 through 7 for the remainder of the input shaft.
Transmission Case
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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BY 3054C Engine
Desarmado y Armado
i01457233
Transmission (Direct Drive) - Remove

SMCS - 3030-011-DD
Removal Procedure
Table 1
Required Tools
8S-7640 Stand 2
A 8S-7611 Tube 2
8S-7615 Pin 2
B 1U-9760 Jack Stand 2
C 1U-7505 Transmisson Jack 1
D 1U-7558 Mounting Brackets 2
E FT-2535 Engine Support Bar Assembly 1
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.
2. Place tooling (A) under rear frame (1) .
3. Place tooling (B) under front axle (2) .
4. Remove inspection plate (3). Install tooling (E) in order to support the engine.
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).
6. Remove four bolts (5) .
7. Repeat Step 6 for the opposite side.
8. Remove two bolts (6) .
9. Disconnect three electrical connectors (7) .
10. Loosen bolt (8) and slide rod assembly (9) off the transmission lever.
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.
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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BY 3054C Engine
Pruebas y Ajustes
416D, 420D, 424D, 428D, 430D, 432D, 438D and 442D Backhoe Loaders Transmission (Direct Drive)
i02425361
Transmission and Torque Converter - Test

SMCS - 3060-081-HR; 3101-081
Table 1
Required Tools
Part Number Tools Needed Qty
6V-3121 Multitach 1
6V-3965 Fitting As 3
198-4240 Digital Pressure Indicator 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 2 Wheel Drive All Wheel Drive
Pump Pressure at High Idle 1525 ± 175 kPa (220 ± 25 psi)
Forward Clutch Pressure at Low Idle

1410 ± 100 kPa (205 ± 15 psi)
A result within
Reverse Clutch Pressure at Low Idle
25 kPa (3.6 psi) of Forward clutch pressure
Lubrication Pressure at Low Idle

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.
1. Remove ten bolts (2) and cover (1) .
2. Remove two bolts (3) and plate (4) .
3. Remove two bolts (5) and plate (6) . Remove floor mat (7) .
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.
(10) Transmission pump pressure
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 71°C (138 to 160°F). 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 93°C (194 to 200°F). 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 2084 ± 75 RPM
80 hp 2143 ± 75 RPM
85 hp 2210 ± 75 RPM
93 hp 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.
(12) Forward clutch pressure
(13) Reverse clutch pressure
2. At pressure taps (12) and (13) , 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)
(15) All wheel drive pressure
2. Start the engine and run the engine at low idle.
(16) All wheel drive switch
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

Producto: BACKHOE LOADER

(2) Torque converter inlet

(3) Reverse clutch

(4) Forward clutch

(5) Lubrication pressure

(6) All wheel drive (if equipped)

Producto: BACKHOE LOADER

Transmission (Direct Drive) - Assemble

1. Install bearing cups (60), (61), (62), (63), and (64) .

(Direct Drive) Input Shaft

2. Install the seals on piston (56) .

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

8. Install the input shaft.

(Direct Drive) Reverse Shaft

2. Install the reverse shaft.

(Direct Drive) Shaft

2. Install the shaft.

(Direct Drive) Output Shaft (Rear)

1. Install gear (42) .

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

6. Install the output shaft (rear) in the transmission.

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

(Direct Drive) Output Shaft (Front)

1. Install seals on piston (22) .

2. Install piston (22), spring (19), and retainer (21) .

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) .

7. Remove transmission (1) from tooling (F) .

Producto: BACKHOE LOADER

Transmission (Direct Drive) - Disassemble

Refer to Special Publication, NENG2500, "Caterpillar Tools

Dispose of all fluids according to local regulations and

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) .

9. Remove gear (59) from the clutch pack.

1. Remove bearing cups (60), (61), (62), (63), and (64) .

Producto: BACKHOE LOADER

Transmission (Direct Drive) - Remove

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

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