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Testing and Adjusting
IT28G Integrated Toolcarrier and 924G, 924Gz and 928G Wheel Loaders Power Train
Media Number - RENR6425-01 Publication Date - 2002/11/01 Date Updated - 2002/11/19
i01779978
Transmission Pressures - Test and Adjust
SMCS - 3030-025; 3030-081; 3073-025; 3073-081
Personal injury or death can result from sudden machine movement.
Sudden movement of the machine can cause injury to persons on or
near the machine.
Prevent possible injury by performing the procedure that follows before
working on the machine.
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.
1. Park the machine on a smooth, level surface.
2. Place the transmission direction and speed control lever (if equipped) in the NEUTRAL position and
in any speed position. Shift the transmission direction control switch (if equipped) to the NEUTRAL
position.
3. Lower the bucket or the work tool to ground.
4. Engage the parking brake and stop the engine.
5. Place blocks in front of the wheels and behind the wheels.
6. Install the steering frame lock.
7. Allow only authorized personnel on the machine. Keep unauthorized personnel off the machine and in
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clear sight of the operator.
Note: All tests and all adjustments must be made while the transmission oil is at normal operating
temperature.
NOTICE
Do not connect or disconnect hose fittings to or from the quick
disconnect nipples when there is pressure in the system. This will
prevent damage to the seals that are in the fitting.
Table 1
Required Tools
Part Number Description Qty
1U-5481 Pressure Gauge Group 1
1U-5482 Pressure Adapter Group 1
Test Procedures
Test for the Transmission Clutch Pressure
Use the following procedure to check the pressure of the direction clutch oil and the speed clutch oil.
The machine is equipped with the following modulating valves:
! Modulating valve for clutch 1 (1) (forward low)
! Modulating valve for clutch 2 (2) (forward high)
! Modulating valve for clutch 3 (3) (reverse)
! Modulating valve for clutch 4 (4) (second speed)
! Modulating valve for clutch 5 (5) (third speed and fourth speed)
! Modulating valve for clutch 6 (6) (first speed)
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Illustration 129 g00913305
Illustration 130 g00913306
1. Install the correct hose assembly from the 1U-5482 Pressure Adapter Group on pressure tap (1)
through pressure tap (6). Attach the opposite end of the hose assembly to the 0 to 3400 kPa (0 to 580
psi) pressure gauge in the 1U-5481 Pressure Gauge Group .
2. Engage the parking brake. Shift the transmission direction and speed control lever to the NEUTRAL
position. Shift the transmission direction control switch to the NEUTRAL position (if equipped). Start
the engine and operate the engine at low idle.
3. Ensure that the transmission neutralizer override is enabled. The transmission neutralizer override is
enabled when the transmission neutralizer override switch is illuminated.
4. Place the autoshift switch in the MANUAL position.
Note: The machine can drive through the service brakes when the machine is at high idle.
5. Depress the brake pedal and hold the brake pedal. Release the parking brake. Make sure that the
machine is in first speed. Watch the pressure gauges. Shift the transmission direction and speed
control lever from the NEUTRAL position to the FORWARD position. Increase the engine speed to
high idle. Make sure that the transmission oil is at normal operating temperature. The needle on the
pressure gauge for clutch 1 should rise. The needle on the pressure gauge for clutch 6 should rise. The
pressure readings must be within the values in Table 3.
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With the transmission in the FORWARD position, shift through the remaining forward speeds and
note the clutch pressures for each speed. Return to the FIRST SPEED position. Use the transmission
direction and speed control lever. The pressure reading for each energized clutch must be within the
values in Table 3. This checks the pressure of all the speed clutches.
6. Perform Step 5 for all reverse speeds. The same pressure levels should be noted in all reverse speeds.
7. Perform 5 and 6 with the engine at low idle. The same pressures should be observed. If the pressures
are lower, there is a leak in the transmission control system.
Table 2
First Second Third Fourth First Second Third
speed speed speed speed Neutral speed speed speed
forward forward forward forward reverse reverse reverse
Clutch 1
(forward X X X
low)
Clutch 2
(forward X
high)
Clutch 3
X X X
(reverse)
Clutch 4
(second X X
speed)
Clutch 5
(third speed
X X X X
and fourth
speed)
Clutch 6
(first speed) X X
Table 3
Transmission Pressures
Pressure Tap Specification Actual Pressure
Modulating valve for clutch 1
2400 ± 170 kPa (350 ± 25 psi)
Modulating valve for clutch 2
2400 ± 170 kPa (350 ± 25 psi)
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Modulating valve for clutch 3
2400 ± 170 kPa (350 ± 25 psi)
Modulating valve for clutch 4
2400 ± 170 kPa (350 ± 25 psi)
Modulating valve for clutch 5
2400 ± 170 kPa (350 ± 25 psi)
Modulating valve for clutch 6
2400 ± 170 kPa (350 ± 25 psi)
Adjustment for the Transmission Clutch Pressure
The transmission clutches should have the same clutch pressure. If the pressure readings for all of the
transmission clutches are not within the values that are in Table 3, the transmission relief valve may need to
be adjusted. Refer to "Adjustment for the Transmission Pump Pressure" for the proper adjustment procedure.
If one of the transmission clutch pressures are not within the specification, check that the modulating valve
for that clutch is operating correctly.
Test for the Lubrication Oil Pressure
Use the following procedure to check the pressure of the transmission lubrication oil.
Illustration 131 g00889657
The inlet for the transmission lubrication oil is located on the right side of the machine.
1. Install the correct adapter at pressure tap (7) .
2. Install the correct hose assembly from the 1U-5482 Pressure Adapter Group on pressure tap (7).
Attach the opposite end of the hose assembly to the 0 to 400 kPa (0 to 58 psi) pressure gauge in the
1U-5481 Pressure Gauge Group .
3. Start the engine and operate the engine at high idle. Observe the pressure gauge. With the oil at normal
operating temperature, the lubrication oil pressure must be within the values in Table 3.
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Table 4
Transmission Pressure
Pressure Tap Specification Actual Pressure
Transmission lubrication
170 ± 34 kPa (25 ± 5 psi)
Test for the Transmission Oil Pump Pressure
Use the following procedure to check transmission oil pump pressure.
Illustration 132 g00913310
1. Install the correct hose assembly from the 1U-5482 Pressure Adapter Group on pressure tap (8) .
Attach the opposite end of the hose assembly to the 0 to 3400 kPa (0 to 580 psi) pressure gauge in the
1U-5481 Pressure Gauge Group .
2. Start the engine and operate the engine at high idle. Observe the pressure gauge. With the oil at normal
operating temperature, the transmission oil pump pressure must be within the values in Table 5.
Table 5
Transmission Pressure
Pressure Tap Specification Actual Pressure
Transmission oil pump
2400 ± 170 kPa (350 ± 25 psi)
Adjustment for the Transmission Oil Pump Pressure
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Illustration 133 g00913312
The transmission relief valve (10) is located below the modulating valves.
Illustration 134 g00889597
If the transmission oil pump pressure at pressure tap (8) is not within the values in Table 6, adjust the spring
of the transmission relief valve (10). Use the following procedure.
1. Remove cover (11) .
2. Turn adjustment screw (12) in the proper direction.
Turning the adjustment screw clockwise increases pump pressure. Turning the adjustment screw
counterclockwise decreases pump pressure. One full turn of the adjustment screw changes pump
pressure 160 kPa (23 psi).
3. Install cover (11) .
4. Check the transmission oil pump pressure again. Make sure that the transmission oil pump pressure is
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within the value in Table 6.
Table 6
Transmission Pressure
Pressure Tap Specification Actual Pressure
Transmission oil pump
2400 ± 170 kPa (350 ± 25 psi)
Test for the Torque Converter Inlet Pressure
Illustration 135 g00913315
Illustration 136 g00913316
Pressure tap (13) is located on the transmission relief valve. The transmission relief valve is located below
the modulating valves.
1. Install the correct hose assembly from the 1U-5482 Pressure Adapter Group on pressure tap (13).
Attach the opposite end of the hose assembly to the 0 to 2000 kPa (0 to 290 psi) pressure gauge in the
1U-5481 Pressure Gauge Group .
2. Start the engine and operate the engine at high idle. Observe the pressure gauge. With the oil at normal
operating temperature, the torque converter inlet pressure must be below the values in Table 7.
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Table 7
Transmission Pressure
Pressure Tap Specification Actual Pressure
Torque converter inlet
895 kPa (130 psi) maximum
Test for the Torque Converter Outlet Pressure
Illustration 137 g00910058
Illustration 138 g00913318
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Pressure tap (14) is located on the top of the transmission.
1. Install the correct hose assembly from the 1U-5482 Pressure Adapter Group on pressure tap (14).
Attach the opposite end of the hose assembly to the 0 to 2000 kPa (0 to 290 psi) pressure gauge in the
1U-5481 Pressure Gauge Group .
2. Start the engine and operate the engine at high idle. Observe the pressure gauge. With the oil at normal
operating temperature, the torque converter inlet pressure must be within the values in Table 8.
Table 8
Transmission Pressure
Pressure Tap Specification Actual Pressure
Torque converter outlet
585 ± 170 kPa (85 ± 25 psi)
Transmission Pressures
Table 9
Transmission Pressure
Actual Pressure
Pressure Tap Specification
Modulating valve for clutch 1 (forward low) 2400 ± 170 kPa (350 ± 25
psi)
Modulating valve for clutch 2 (forward high) 2400 ± 170 kPa (350 ± 25
psi)
Modulating valve for clutch 3 (reverse) 2400 ± 170 kPa (350 ± 25
psi)
Modulating valve for clutch 4 (second speed) 2400 ± 170 kPa (350 ± 25
psi)
Modulating valve for clutch 5 (third speed and fourth
2400 ± 170 kPa (350 ± 25
speed)
psi)
Modulating valve for clutch 6 (first speed) 2400 ± 170 kPa (350 ± 25
psi)
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Torque converter outlet 585 ± 170 kPa (85 ± 25 psi)
Transmission lubrication
170 ± 34 kPa (25 ± 5 psi)
Transmission oil pump 2400 ± 170 kPa (350 ± 25
psi)
Torque converter inlet 895 kPa (130 psi) maximum
Copyright 1993, 2002 Caterpillar Inc. Sat Nov 30 13:24:25 UTC-0200 2002
All Rights Reserved.
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