Worksheets
Show/hide table
| Power Train | |||
|---|---|---|---|
| Machine Model | Date Today | ||
| Machine Serial Number | Machine Hours | ||
| Serial Number of Converter | Hours | ||
| ECM Flash File (Transmission) | |||
Show/hide table
| Visual Checks | |||
|---|---|---|---|
| Oil level | Oil Viscosity | ||
| Air in Oil | Oil Filter Examination |
||
| Water in Oil | |||
Torque Converter Test
Show/hide table
| TEST | SPECS | ACTUAL |
|---|---|---|
| Torque Converter Oil Temperature (during tests) | > 80 °C (176 °F) < 121 °C (250 °F) |
|
| Torque Converter Charging Filter Restriction | Max restriction 345 ± 21 kPa (50 ± 3 psi) |
Low idle: High idle: |
| Torque Converter Inlet Relief Pressure Measured at pressure tap "P1" |
Low idle 140 ± 70 kPa (20 ± 10 psi) High idle 690 ± 70 kPa (100 ± 10 psi) |
Low idle: High idle: Stall: |
| Torque Converter Outlet Relief Pressure Measured at pressure tap "P1" |
Low idle 100 ± 70 kPa (15 ± 10 psi) High idle 450 ± 70 kPa (65 ± 10 psi) |
Low idle: High idle: Stall: |
| Torque Converter Stall RPM (1) | 1530 ± 65 RPM | |
| Transmission Charge Pressure | Low idle 2340 ± 275 kPa (340 ± 40 psi) High idle 2585 ± 170 kPa (375 ± 25 psi) |
Low idle: High idle: |
| Lockup Clutch Maximum Pressure NEUTRAL/CONVERTER DRIVE/HIGH IDLE |
0.0 ± 35 kPa (0.0 ± 5 psi) |
|
| Lockup Clutch Maximum Pressure NEUTRAL/DIRECT DRIVE/LOW IDLE (2) |
1930 ± 140 kPa (280 ± 20 psi) |
Show/hide table
| ( 1 ) | Torque Limiting strategy reduces engine RPM. |
| ( 2 ) | Use Transmission Calibration Procedure |
Transmission Tests
Transmission Test 1
Show/hide table
| TEST | SPECS | ACTUAL |
|---|---|---|
| Transmission Oil Temperature (during tests) | > 80 °C (175 °F) < 121 °C (250 °F) |
|
| Transmission Charging Filter Restriction | Max restriction 345 ± 21 kPa (50 ± 3 psi) |
Low idle: High idle: |
| Transmission Charging Pressure (Main Relief) | Low idle 2310 ± 138 kPa (335 ± 20 psi) High idle 2650 ± 138 kPa (385 ± 20 psi) |
Low idle: High idle: |
| Transmission Clutch Latching Pressure (1) | Low idle: 2206 ± 138 kPa (320 ± 20 psi) High idle: 2482 ± 138 kPa (360 ± 20 psi) |
Low idle: High idle: |
| Transmission Lubrication Oil Pressure at Rear Transmission Module (2) | Low idle 105 ± 35 kPa (15 ± 5 psi) High idle 480 ± 100 kPa (70 ± 15 psi) |
Low idle: High idle: |
| Transmission Lubrication Oil Pressure at Front Transmission Module (3) | Low idle 55 kPa to 95 kPa (8 psi to 14 psi) High idle 380 kPa to 550 kPa (55 psi to 80 psi) |
Low idle: High idle: |
| Transmission Lubrication Oil Pressure - Clutch 6 and 7 at Rear Transmission Module (4) | Low idle 62 ± 14 kPa (9 ± 2 psi) High idle 345 ± 70 kPa (50 ± 10 psi) |
Low idle: High idle: |
Show/hide table
| ( 1 ) | At pressure tap |
| ( 2 ) | At sensor location |
| ( 3 ) | At front transmission module pressure tap |
| ( 4 ) | At bottom of lube valve. Transmissions equipped with an updated lubrication manifold will see reduced lube pressure for clutches 6 and 7. For transmission with an updated lubrication manifold, no lube test is now required for clutches 6 and 7. |
Transmission Test 2
Show/hide table
| CLUTCH PRESSURE AT LOW IDLE | ||||
|---|---|---|---|---|
| CLUTCH | CONVERTER DRIVE | ACTUAL | GEAR | CLUTCHES ENGAGED |
| 2 | 2067± 138 kPa (300 ± 20 psi) |
NEUTRAL | 2 | |
| 2 | 2067 ± 138 kPa (300 ± 20 psi) |
REVERSE | 2 - 7 | |
| 3 | 2067 ± 138 kPa (300 ± 20 psi) |
FIRST | 3 - 6 | |
| 6 (1) | 2310 ± 138 kPa (335 ± 20 psi) |
FIRST | 3 - 6 | |
| 7 (2) | 2310 ± 138 kPa (335 ± 20 psi) |
REVERSE | 2 - 7 | |
| Transmission Oil Temperature (during tests) | > 80 °C (175 °F) < 121 °C (250 °F) |
|||
Show/hide table
| ( 1 ) | Clutch 6 is limited by pump pressure in CONVERTER DRIVE. |
| ( 2 ) | Clutch 7 is limited by pump pressure in CONVERTER DRIVE. |
Rear Axle Tests
Rear Axle Test 1
Show/hide table
| Engine at LOW IDLE, Pump Drive Diverter "OFF", Final Drive Bypass "ON" | ||
|---|---|---|
| TEST | SPECS | ACTUAL |
| Differential Temperature | 85 ° to 135 °C (185 ° to 275 °F) |
|
| Engine RPM | 700 ± 10 | |
| Rear Axle Pump Drive Pressure | < 13780 kPa (2000 psi) |
|
| Differential Oil Filter Pressure | 62 to 380 kPa (9 to 55 psi) |
|
| Final Drive Oil Filter Pressure | 28 to 90 kPa (4 to 13 psi) |
|
Rear Axle Test 2
Show/hide table
| Engine at HIGH IDLE, Pump Drive Diverter "OFF", Final Drive Bypass "ON" | ||
|---|---|---|
| TEST | SPECS | ACTUAL |
| Differential Temperature | 85 ° to 135 °C (185 ° to 275 °F) |
|
| Engine RPM | 1950 ± 20 | |
| Rear Axle Pump Drive Pressure | < 13780 kPa (2000 psi) |
|
| Differential Oil Filter Pressure | 520 to 1100 kPa (75 to 160 psi) |
|
| Final Drive Oil Filter Pressure | 95 to 200 kPa (14 to 29 psi) |
|
Rear Axle Test 3
Show/hide table
| Engine at LOW IDLE, Pump Drive Diverter "OFF", Final Drive Bypass "OFF" | ||
|---|---|---|
| TEST | SPECS | ACTUAL |
| Differential Temperature | 85 ° to 135 °C (185 ° to 275 °F) |
|
| Engine RPM | 700 ± 10 | |
| Rear Axle Pump Drive Pressure | < 13780 kPa (2000 psi) |
|
| Differential Oil Filter Pressure | 90 to 370 kPa (13 to 54 psi) |
|
| Final Drive Oil Filter Pressure | 62 to 500 kPa (9 to 72 psi) |
|
Rear Axle Test 4
Show/hide table
| Engine at LOW IDLE, Pump Drive Diverter "ON", Final Drive Bypass "ON" | ||
|---|---|---|
| TEST | SPECS | ACTUAL |
| Differential Temperature | 85 ° to 135 °C (185 ° to 275 °F) |
|
| Engine RPM | 700 ± 10 | |
| Rear Axle Pump Drive Pressure | Residual Pressure Only | |
| Differential Oil Filter Pressure | 0 to 14 kPa (0 to 2 psi) |
|
| Final Drive Oil Filter Pressure | 0 to 14 kPa (0 to 2 psi) |
|
Caterpillar Information System:
120H and 135H Motor Graders Operator Controls
735 and 740 Articulated Trucks and 735 and 740 OEM Articulated Trucks Steering, Suspension, and Body Hoist Hydraulic Systems Steering System (Schematic)
938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Vane Pump (Braking) - Install
938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Loader Frame and Rear Frame - Connect
797 Off-Highway Truck Power Train Transmission - Test
797 Off-Highway Truck Power Train Torque Converter - Test
938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Vane Pump (Braking) - Remove
AP-655C and BG-2255C Asphalt Pavers Propel System Piston Pump (Propel)
938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Piston and Vane Pump (Steering and Implement) - Install
3034 Engine for Caterpillar Built Machines Pistons and Connecting Rods - Install - Fractured Connecting Rod
2003/04/01 New Flash File Software Is Used for Product Link 151/201 {7620}
CP-663E, CS-663E and CS-683E Paving Compactors Machine Systems Hydraulic Oil Filter
Procedure for Replacement of Air Conditioner Components{7320} Procedure for Replacement of Air Conditioner Components{7320}
938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Piston Pump (Hydraulic Fan) - Remove
735 and 740 Articulated Trucks and 735 and 740 OEM Articulated Trucks Steering, Suspension, and Body Hoist Hydraulic Systems Hoist System (Schematic)
735 and 740 Articulated Trucks and 735 and 740 OEM Articulated Trucks Steering, Suspension, and Body Hoist Hydraulic Systems Suspension System (Schematic)
735 and 740 Articulated Trucks and 735 and 740 OEM Articulated Trucks Steering, Suspension, and Body Hoist Hydraulic Systems Braking System (Schematic)
735 and 740 Articulated Trucks and 735 and 740 OEM Articulated Trucks Steering, Suspension, and Body Hoist Hydraulic Systems Hoist, Steering, Suspension, and Fan Drive System (Schematic)
938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Machine Systems Piston Pump (Hydraulic Fan) - Install
3034 Engine for Caterpillar Built Machines Pistons and Connecting Rods - Remove - Fractured Connecting Rod
TH350B, TH360B, TH460B and TH560B Telehandlers Engine Supplement Engine - Install
TH210 and TH215 Telehandlers Machine Systems Diverter Valve - Remove and Install
TH210 and TH215 Telehandlers Machine Systems Trailer Brake Valve (Hydraulic) - Remove and Install
TH350B, TH360B, TH460B and TH560B Telehandlers Engine Supplement Engine Mount (Rear) - Remove