- Integrated Toolcarrier:
- IT38F (S/N: 6FN1-UP; 5DR1-UP)
- IT38G (S/N: 7BS1-UP; 1CW1-UP)
- Wheel Loader:
- 938F (S/N: 1KM1-UP; 2RM1-UP; 8SM1-UP; 7SN1-UP)
- 938G (S/N: 4YS1-2709,1-UP; 6WS1-UP; 8RS1-UP; 9HS1-UP)
Introduction
| Revision | Summary of Changes in REHS1636 |
| 03 | Standardized. |
| 02 | Added new introduction and Canceled Part Numbers section. |
© 2015 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.
This special instruction contains the necessary information that is required to bench test a specific transmission arrangement. Refer to Table 2 for the correct arrangements. Bench testing the transmission ensures correct assembly and operation of the component. Rotating a transmission provides the most conclusive evaluation. Testing allows the dealer to ensure that the transmission will operate properly in the machine. The specifications in this guideline are specific to bench testing the component. Every effort has been made in order to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This guideline must be used with the latest technical information that is available from Caterpillar.
For questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. In order to address an urgent issue, use the following resources in order to communicate your request to Caterpillar Repair Process Engineering:
- Caterpillar Dealer Technical Communicator
- Dealer Solution Network
- Caterpillar Technical Representative
- Knowledge Network
| Machine Model | Transmission Arrangement |
| 938F | 6Y-8245 |
| 938G | 196-2780, 170-1856 |
| IT38F | 6Y-8245 |
| IT38G | 6Y-8245, 196-2780, 170-1856 |
Canceled Part Numbers and Replaced Part Numbers
This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.
Important Safety Information
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| Illustration 1 | g02139237 |
Follow all safety warnings. Most accidents that involve product operation, maintenance, or repair are caused by failure to observe safety warnings. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. Personnel must be properly trained in order to perform maintenance, repair, or operate any machine. Safety precautions and warnings are provided this instruction and on Caterpillar products. These warnings should be observed before performing any procedures. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are not all inclusive.
The hazards are identified by the "Safety Alert Symbol" which is followed by a "Signal Word" such as "DANGER", "WARNING, or" "CAUTION". The "WARNING" Safety Alert Symbol is shown in illustration below.
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| Illustration 2 | g00008666 |
This safety alert symbol means:
Pay Attention!
Become Alert!
Your Safety is Involved.
The message that appears under the safety alert symbol explains the hazard.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.
The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.
Collecting the Test Data
Since conditions vary for each test bench, use the data that is collected from your test bench. The collected data is used to compare test results. The data should be collected and maintained by the operator.
Data from each transmission arrangement is collected and stored. Averages from each transmission arrangement are often used in order to compare values on portions of transmission tests. Always compare data that is collected from the same transmission arrangement that is being tested. Averages for the last 20 transmission arrangements should be maintained.
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Personal injury or death can result from escaping fluid under pressure. 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. Always use a board or cardboard when checking for a leak. |
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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. |
|
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Personal injury or death can result from not following the proper procedures. To avoid the possibility of injury or death, follow the established procedure. |
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Tools Needed
Note: Pressures will be sensitive to tooling setup. The diameter of the hose, the diameter of a fitting, and additional filtering can affect pressure. The required tools that are listed in Table 3 were used to develop this test procedure.
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 1U-9585 | Mounting Block Gp | 1 |
| 1U-9584 | Rail As | 2 | |
| 4C-9998 | Bracket As | 1 | |
| 1U-9035 | Crossmember As | 1 | |
| B | 1U-5798 | Drive Adapter Gp | 1 |
| C | 1U-6698 | Adapter As (Spindle) | 1 |
| 0S-1588 | Bolt (3/8-16X1.25 inch) | 6 | |
| 5M-2894 | Hard Washer | 12 | |
| D | 1U-5999 | Spindle Gp | 1 |
| 1A-1460 | Bolt (1/2-13X2.00 inch) | 4 | |
| 3B-4508 | Lockwasher | 4 | |
| E | 1U-6721 | Adapter (Drive) | 1 |
| F | 1U-9131 | Drive Adapter (Key) (1) | 1 |
| G | 1U-9359 | Drive Adapter (2) | 1 |
| H | 1U-9722 | Load Binder As (Ratchet Type) | 3 |
| S | 1U-9037 | Adapter As | 1 |
| 2N-5243 | O-Ring Seal | 1 | |
| J | 1U-6233 | Adapter As | 1 |
| 6V-3940 | Bolt (M8X1.25X25 mm) | 3 | |
| 9M-1974 | Hard Washer | 3 | |
| 5N-2918 | Fitting | 1 | |
| 5L-6669 | Reducer Bushing | 1 | |
| 140-5979 | Elbow | 1 | |
| 1U-9879 | Adapter | 1 | |
| K | 1U-9872 | 4 Bolt Flange | 1 |
| 6V-1820 | Hex Bolt (M10X1.5X30 mm) | 4 | |
| 8C-9024 | Fitting As (Plain) | 1 | |
| L | 1P-4577 | Half Flange | 2 |
| 6V-1820 | Bolt (M10X1.5X30 mm) | 4 | |
| 6V-5839 | Washer | 4 | |
| 1U-8297 | Adapter | 1 | |
| 1U-8301 | Fitting | 1 | |
| 6V-4144 | Coupler | 1 | |
| 8C-9024 | Fitting As (Plain) | 1 | |
| M | 1U-9872 | 4 Bolt Flange | 1 |
| 9X-6032 | Hex Bolt (M10X1.5X30 mm) | 4 | |
| 8C-9024 | Fitting As (Plain) | 1 | |
| N | 8C-9024 | Fitting As (Plain) | 1 |
| 8C-9025 | Quick Coupler | 1 | |
| 3B-7749 | Fitting | 1 | |
| 120-6843 | Ball Valve | 1 | |
| T | 1P-4577 | Half Flange | 2 |
| 6V-1820 | Bolt (M10X1.5X30 mm) | 4 | |
| 6V-5839 | Washer | 4 | |
| 1U-8297 | Adapter | 1 | |
| 1U-8301 | Fitting | 1 | |
| 6V-4144 | Coupler | 1 | |
| 8C-9024 | Fitting As (Plain) | 1 | |
| P | 9U-7500 | Transmission Analyzer Tool Gp | 1 |
| OR | |||
| 277-2362 | Transmission Analyzer III Gp | 1 | |
| 306-0397 | Extension Cable | 1 | |
| 9U-7497 | Adapter Cable As | 1 | |
| 1U-9480 | Cable Adapter | 7 | |
| Q | 8T-0862 | Pressure Gauge (-100 to 500 kPa (-15 to 72 psi)) | 1 |
| 6V-4144 | Coupler | 1 | |
| R | 8T-0855 | Pressure Gauge (0 to 4,000 kPa (0 to 580 psi)) | 5 |
| 6V-4144 | Coupler | 5 | |
| ( 1 ) | This drive adapter is used with the small drive shaft. |
| ( 2 ) | This drive adapter is used with the large drive shaft. |
Installation Procedure
- Install Tooling (A) on the test bench.
 | |
| Illustration 3 | g03864380 |
- Remove threaded plug (1), if necessary.
 | |
| Illustration 4 | g01038938 |
- Remove drain plug (2) .
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| Illustration 5 | g01038939 |
- Use a hoist to install the transmission to Tooling (A). The weight of the transmission is 700 kg (1545 lb).
 | |
| Illustration 6 | g01065836 |
- Use the mounting locations.
 | |
| Illustration 7 | g01038941 |
 | |
| Illustration 8 | g01038943 |
- Install Tooling (B) on the torque converter.
 | |
| Illustration 9 | g01038945 |
- Install Tooling (C) to the transmission case.
 | |
| Illustration 10 | g01038946 |
- Install Tooling (D) on Tooling (C) .
 | |
| Illustration 11 | g01038947 |
- Tighten the collet on Tooling (D) to connect Tooling (D) to Tooling (B) .
Note: Refer to Special Instruction, SEHS8763, "Assembly and Operation of 1U-5999 Spindle Group Used for Testing Transmissions on Hydraulic Test Bench" for additional information.
 | |
| Illustration 12 | g01038948 |
- Install Tooling (E) to the input shaft of Tooling (D) .
 | |
| Illustration 13 | g01038950 |
- Install Tooling (F) to the input shaft of Tooling (E) .
Note: Tooling (F) will adapt to the small drive shaft. If you are using the large drive shaft, install Tooling (G) on Tooling (F) .
 | |
| Illustration 14 | g01038951 |
- Align the transmission with the input drive shaft.
 | |
| Illustration 15 | g01038952 |
- Connect the input drive shaft to Tooling (F) .
- Install the drive shaft guard.
 | |
| Illustration 16 | g01038953 |
- Tighten all four castle nuts and jack bolts.
 | |
| Illustration 17 | g03802221 |
- Install Tooling (H) to the output end of the transmission.
 | |
| Illustration 18 | g01038955 |
- Install Tooling (H) to the input end of the transmission.
 | |
| Illustration 19 | g01038956 |
- Remove cover (3) .
 | |
| Illustration 20 | g01207517 |
- Remove cover (4) .
 | |
| Illustration 21 | g01207515 |
- Remove cover (5) .
 | |
| Illustration 22 | g01038958 |
- Remove magnetic filter (6) .
 | |
| Illustration 23 | g01038959 |
- Install Tooling (S). Orient the slot in an upward position.
Note: Tooling (S) will divert oil to the suction side of the transmission pump. Also, Tooling (S) will prevent oil from filling the oil pan.
 | |
| Illustration 24 | g03864391 |
- Install Tooling (J) .
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| Illustration 25 | g01038962 |
- Install Tooling (K) .
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| Illustration 26 | g01065838 |
- Install Tooling (L) .
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| Illustration 27 | g01040371 |
- Install Tooling (M) .
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| Illustration 28 | g01065840 |
- Connect Tooling (N) to Tooling (M) .
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| Illustration 29 | g01207519 |
- Install Tooling (T) .
 | |
| Illustration 30 | g03864393 |
- Connect hose assembly (7) from the pump supply to Tooling (J) .
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| Illustration 31 | g01207521 |
- Connect hose assembly (8) from Tooling (K) to No. 1 flow meter inlet.
 | |
| Illustration 32 | g01207522 |
(8) Pump Flow | |
- Connect hose assembly (9) from No. 1 flow meter outlet to Tooling (L) .
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| Illustration 33 | g01207523 |
(9) Supply Flow | |
- Connect hose assembly (10) from Tooling (N) to No. 2 flow meter inlet.
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| Illustration 34 | g01207529 |
(10) Torque Converter Outlet | |
- Connect hose assembly (11) from No. 2 flow meter outlet to Tooling (T) .
 | |
| Illustration 35 | g01207530 |
(11) Transmission Lubrication Oil | |
- Connect lube line (12) from the test bench to Tooling (D). Maintain an oil pressure of 275 kPa (40 psi).
 | |
| Illustration 36 | g01207531 |
(12) Spindle Lubrication | |
- Connect three pressure gauges to pressure taps (13), (14), and (15) .
 | |
| Illustration 37 | g01038982 |
(13) "P3" Pressure (14) "P1" Pressure (15) "P2" Pressure | |
Note: If you are using individual pressure gauges to measure the pressures, refer to Table 3 for the correct pressure gauges.
- Connect pressure gauge (16) to Tooling (T) .
 | |
| Illustration 38 | g01207532 |
(16) Transmission Lubrication Pressure | |
- Connect Tooling (P) to six clutch solenoids.
 | |
| Illustration 39 | g01040373 |
(17) Cable connector (1-A) for No. 1 "FORWARD HIGH" solenoid (18) Cable connector (2-B) for No. 2 "REVERSE" solenoid (19) Cable connector (3-C) for No. 3 "FORWARD LOW" solenoid (20) Cable connector (4-D) for No. 4 "FIRST SPEED" solenoid (21) Cable connector (5-E) for No. 5 "SECOND SPEED" solenoid (22) Cable connector (6-F) for No. 6 "THIRD SPEED" solenoid | |
- Connect Tooling (P) to a suitable location.
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| Illustration 40 | g01065846 |
- Cover Tooling (C). Use a clean suitable cover.
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| Illustration 41 | g01038989 |
- Connect Tooling (P) to a power source. Refer to Tool Operating Manual, NEHS0644 or Tool Operating Manual, NEHS0996 for the correct operating instructions.
 | |
| Illustration 42 | g00877510 |
Tooling (P) | |
 | |
| Illustration 43 | g01457869 |
Tooling (P) | |
Test Procedure
TA3 Navigation
- Select "Wheel Loaders".
- Select "938F-24V", "938G-24V", "IT38F-24V", or "IT38G-24V".
Harness Test (TA3 only)
- Make sure that the harness is properly connected.
- Use Tooling (P) to perform the harness test.
- Record the values in Table 7.
Note: Do not continue testing until Harness Test passes.
Solenoid Test (TA2 only)
- Make sure that the harness is properly connected.
- Use Tooling (P) to perform the solenoid test.
- Record the values in Table 7.
Note: Do not continue testing until Solenoid Test passes.
Start Checks
- If you are using SAE 10W oil, warm the oil to 50 °C (125 °F). If you are using Mobil DTE11 oil, warm the oil to 34 °C (95 °F). Maintain this temperature for the duration of the test.
Note: Refer to Testing and Adjusting, SENR6785-03, "938G Wheel Loader and IT38G Integrated Toolcarrier Power Train" for the correct adjusting procedures.
- With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 850 ± 25 rpm. The input flow should be 53 ± 4 L/min (14 ± 1 US gpm).
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| Illustration 44 | g02720621 |
- Shift the transmission through all directions and through all speed ranges to eliminate air from the transmission controls.
- Confirm the correct clutch engagement with Table 4.
Show/hide table
Table 4 Clutch Engagement Check Gear Cl 1 Cl 2 Cl 3 Cl 4 Cl 5 Cl 6 N X F1 X X F2 X X F3 X X F4 X X R1 X X R2 X X R3 X X
- Stop the input rotation.
Relief Valve Check (Torque Converter Inlet)
- With the transmission in the NEUTRAL position, adjust the input rotation to 850 ± 25 rpm.
- Shift the transmission to FORWARD 1.
- Use Tooling (N) to block the flow at the torque converter outlet momentarily.
- The "P3" torque converter inlet pressure must be 1000 ± 140 kPa (145 ± 20 psi).
- Open Tooling (N) .
- Record the value in Table 8.
- Shift the transmission to the NEUTRAL position.
Low Idle Pressure Checks
- With the transmission in the NEUTRAL position, adjust the input rotation to 850 ± 25 rpm.
- Record the input flow, the "P1" pressure, the "P2" pressure, and the "P3" pressure in Table 9.
- Compare the values with the values in Table 6.
- Shift the transmission through each FORWARD and REVERSE speed range. Repeat Steps 2 and 3 for each position.
Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD to REVERSE.
- Shift the transmission to the NEUTRAL position.
- Stop the input rotation.
High Idle Pressure Checks
- With the transmission in the NEUTRAL position, adjust the input rotation to 2200 ± 25 rpm.
- Record the input flow, the oil cooler flow, the "P1" pressure, the "P2" pressure, and the lubrication pressure in Table 10.
- Compare the values with the values in Table 6.
- Shift the transmission through each FORWARD and REVERSE speed range. Repeat Steps 2 and 3 for each position.
Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD to REVERSE.
- Shift the transmission to the NEUTRAL position.
- Stop the input rotation.
Contamination Control
- Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.
- Record the results in Table 11.
- Remove the transmission from the test bench if the test bench oil supply is within specifications.
Transmission Bench Test Data Sheet
| CATERPILLAR | Transmission Bench Test Data Sheet | Test Date:_______ |
| Model:_______ | ||
| Work Order:_______ | Serial No.:_______ | |
Specifications
| General Specifications | ||
| Description | High Idle | Low Idle |
| Input Speed | 2200 ± 25 rpm | 850 ± 25 rpm |
| Input Flow | 136 ± 8 L/min (36 ± 2 US gpm) |
53 ± 4 L/min (14 ± 1 US gpm) |
| Minimum Cooler Flow | 121 L/min (32 US gpm) |
- |
| Max Leakage (2) | 11 L/min (3 US gpm) |
|
| Pressures | ||
| P1 | P2 + 350 ± 70 kPa (P2 + 51 ± 10 psi) |
P2 + 305 ± 70 kPa (P2 + 44 ± 10 psi) |
| P2 | 1930 ± 170 kPa (280 ± 25 psi) |
1930 ± 170 kPa (280 ± 25 psi) |
| P3 (1) | - | 1000 ± 140 kPa (145 ± 20 psi) |
| Lubrication Pressure | 265 ± 50 kPa (38 ± 7 psi) |
- |
| ( 2 ) | Leakage = Input Flow - Cooler Flow |
| ( 1 ) | The transmission is in the FORWARD 1 position. The oil cooler flow is restricted. |
Solenoid Test
| Solenoid Test | Solenoid 1 | Solenoid 2 | Solenoid 3 | Solenoid 4 | Solenoid 5 | Solenoid 6 |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
Relief Valve Check (Torque Converter Inlet)
| Torque Converter Inlet Relief Valve Check (P3) | Input Speed (850 ± 25 rpm) Gear Range FORWARD 1 |
_______kPa _______(psi) |
|||
Low Idle Pressure Checks
Low Idle Pressure Checks |
Input Speed (850 ± 25 rpm) |
|||||||
| Gear Range | N | 1F | 2F | 3F | 4F | 1R | 2R | 3R |
| Input Flow | ||||||||
| Cooler Flow | ||||||||
| "P1" Pressure | ||||||||
| "P2" Pressure | ||||||||
High Idle Pressure Checks
High Idle Pressure Checks |
Input Speed (2200 ± 25 rpm) |
|||||||
| Gear Range | N | 1F | 2F | 3F | 4F | 1R | 2R | 3R |
| Input Flow | ||||||||
| Oil Cooler Flow | ||||||||
| "P1" Pressure | ||||||||
| "P2" Pressure | ||||||||
| Lubrication Pressure | ||||||||
Contamination Control
| ISO Particle Count | Sample the test bench oil supply. |
________/________Particle Count |
| ______________________________________ Technician |
______________________________________ Supervisor |