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Producto: TRUCK
Modelo: 793D TRUCK FDB
Configuración: 793D Off-Highway Truck FDB00001-UP (MACHINE) POWERED BY 3516B Engine

Pruebas y Ajustes
793D Off-Highway Truck Power Train
Número de medio -RENR8327-01 Fecha de publicación -01/02/2007 Fecha de actualización -06/02/2007

i01286928

Transmission Hydraulic Control Primary Clutch Pressure -

Test and Adjust
SMCS - 3073

Número de pieza - 6I-8554

This test will determine if the primary clutch pressures are correctly adjusted.

Personal injury or death can result from sudden machine movement.

Sudden movement of the machine or release of air pressure or oil

pressure can cause injury to persons on or near the machine.

To help prevent possible injury before testing and adjusting any air
system or hydraulic system, perform the procedure in the Testing and
Adjusting, "General Information" section.

Table 1
Tools Needed Qty

6V-6064 Transmission Test Cover (1) 1

8T-0854 Pressure Gauges (

6
1000 kPa (145 psi))

9S-1721 Extension (1/4 inch square drive) 1

9U-6635 Reversible Ratchet 1

FT1775 Transmission Test Cover (1) 1
(1)
Only one transmission test cover is necessary.

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Note: Make sure that the filters and the screens are clean before you test any pressures. Make sure
that the oil is at operating temperature before you perform this test.

Procedure for Manual Shifts of the Transmission

This procedure will save time when the transmission is tested. Shifts can be performed on the
transmission instead of using the transmission shift lever in the operator's station.

NOTICE

To prevent possible damage to the flexible coupling, never manually

shift the transmission by rotating the flexible coupling for the
transmission switch.

1. Be certain that the test cover is installed on the transmission case before any tests are
performed.

2. Be certain that the transmission shift lever is in the NEUTRAL position.

Illustration 1 g00287667

3. Disconnect the wiring harness from the upshift solenoid, the downshift solenoid, and the
lockup solenoid.

4. Remove the plug for the rotary selector spool from the left side of the transmission case
while the engine is stopped.

5. Use a 9S-1721 Extension (1/4 inch square drive) and a 9U-6635 Reversible Ratchet to turn
the transmission rotary selector spool. When the ratchet is fully turned in a clockwise
direction, the rotary selector spool is in the NEUTRAL-1 position. The order of the detent
positions is NEUTRAL-1, NEUTRAL-2, REVERSE, and FIRST speed through SIXTH
speed.

Note: There is approximately 30 degrees of rotation between each detent of the rotary
selector spool.

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Procedure

NOTICE

Make sure the drive axles are removed or disconnect the drive shaft
from the machine for this test or the clutches of the transmission will
be damaged.

1. Remove the drive axles from the machine or disconnect the drive shaft from the torque
converter.

Note: Failure to perform Step 1 can result in damage to the transmission clutches.

Illustration 2 g00533283

(1) Load piston plugs (six)

(M) Pressure tap for the pilot oil of the transmission hydraulic control

2. Remove the solenoid guard and the large cover from the top of the transmission case. Install
the FT1775 Transmission Test Cover in the place of the large cover. Use four bolts to hold
the test cover in position.

Alternate Step 2. Remove the small cover from the large cover. Install the 6V-6064
Transmission Test Cover in the place of the large cover. Use four bolts to hold the test cover
in position.

Note: If a FT1775 Transmission Test Cover is used, a gauge can be installed at pressure tap
(M) in order to check the pilot pressure. If a 6V-6064 Transmission Test Cover is used, be
certain that the plug is installed at pressure tap (M) .

3. Remove six load piston plugs (1) .

4. Reinstall the test cover. Install four bolts in order to hold the test cover in place.

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Illustration 3 g00684007

Installation of the test gauge for pressure

(A) Pressure tap for the No. 2 clutch

(B) Pressure tap for the No. 1 clutch

(C) Pressure tap for the No. 3 clutch

(E) Pressure tap for the No. 4 clutch

(F) Pressure tap for the No. 5 clutch

(G) Pressure tap for the No. 6 clutch

(H) This pressure tap is not used.

(M) Pressure tap for the pilot oil of the transmission hydraulic control

5. Connect 8T-0854 Pressure Gauges (1000 kPa (145 psi)) to the nipples at pressure taps (A),
(B), (C), (E), (F), and (G) .

6. Start the engine. Run the engine at the low idle rpm with the transmission in NEUTRAL-1.

7. Record the pressures on the gauges. Use Table 2 to record the measurements.

8. Use a 9U-6635 Reversible Ratchet and a 9S-1721 Extension (1/4 inch square drive) in order
to move the transmission rotary selector spool to the NEUTRAL-2 position.

Note: An 8T-5200 Signal Generator/Counter can be used to shift the transmission during
the diagnostic tests instead of manual shifting.

9. Record the pressures on the gauges. Use Table 2 to record the measurements.

10. Manually shift the transmission into REVERSE and into all the forward speeds. Record the
pressures on the gauges during each shift.

11. Stop the engine with the transmission rotary selector spool in NEUTRAL-1.

12. Compare the actual primary clutch pressure that is recorded on Table 2 and the pressure for
each clutch that is provided in Table 2.

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13. After the primary pressures are correctly set, the maximum clutch pressures must be
checked. Perform the Testing and Adjusting, "Transmission Hydraulic Control Clutch
Pressure - Test".

Note: If the primary clutch pressures are set correctly and the maximum clutch pressures are
incorrect, check the components of the pressure control valve for the correct part number
and for the correct installation. The primary clutch pressure must be set correctly.

14. Remove the pressure gauges and the test cover. Install load piston plugs (1). Install the large
cover, the small cover, and the solenoid guard. Connect the wiring harness to the solenoids.

15. Install the drive axles on the machine or install the drive shaft on the machine.

Illustration 4 g00532485

Pressure control valve

(1) Load piston plugs (six)

(2) Modulation reduction valves (seven)

(3) Load piston orifice

(4) Decay orifice plugs (five)

(5) Shims (seven places)

(6) Selector piston plugs (seven)

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(7) Selector piston (seven)

(8) Load piston (seven)

(9) Inner springs (six)

(10) Outer springs (seven)

(A) Housing for station "A"

(B) Housing for station "B"

(C) Housing for station "C"

(D) Housing for station "D"

(E) Housing for station "E"

(F) Housing for station "F"

(G) Housing for station "G"

(H) Location for station "H"

Table 2
Primary Clutch Pressure

Station (1) (2) "A" "B" "C" "E" "F" "G"

Clutch No. 2 No. 1 No. 3 No. 4 No. 5 No. 6

Engaged
Speed Pressure (3) Pressure (3) Pressure (3) Pressure (3) Pressure (3) Pressure
Clutches
Position

NEUTRAL
3 0 0 480 kPa 0 0
-1
(70 psi)
NEUTRAL
-1 (actual) 3

NEUTRAL
1 0 475 kPa 0 0 0
-2
(69 psi)

NEUTRAL
-2 (actual) 1

REVERSE 1 and 6
0 475 kPa 0 0 0 425 kPa
(69 psi) (62 psi)

REVERSE 1 and 6
(actual)

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1 and 5
FIRST 0 475 kPa 0 0 450 kPa
(69 psi) (65 psi)
FIRST 1 and 5
(actual)

SECOND 2 and 5
525 kPa 0 0 0 450 kPa
(76 psi) (65 psi)

SECOND 2 and 5
(actual)

1 and 4
THIRD 0 475 kPa 0 425 kPa 0
(69 psi) (62 psi)
THIRD 1 and 4
(actual)

FOURTH 2 and 4
525 kPa 0 0 425 kPa 0
(76 psi) (62 psi)

FOURTH 2 and 4
(actual)

1 and 3
FIFTH 0 475 kPa 480 kPa 0 0
(69 psi) (70 psi)

FIFTH 1 and 3
(actual)

2 and 3
SIXTH 525 kPa 0 480 kPa 0 0
(76 psi) (70 psi)

SIXTH 2 and 3
(actual)
(1)
Station "H" is not used.
(2)
Station "D" does not control a clutch. When the lockup clutch solenoid is activated, Station "D" reduces the
pressure setting of the dual stage relief valve. The action of Station "D" on the ICM transmission hydraulic
control maintains the oil in the clutch supply rail at a reduced pressure. Refer to the Testing and Adjusting,
"Transmission Hydraulic Control (Pressure Pack) - Test and Adjust" for the proper procedure to adjust Station
"D".
(3)
The tolerance is + 50 - 35 kPa (+ 7 - 5 psi).

Table 3
Shims For The Pressure Control Valve
Pressure Change Per Shim (1)

Station (2) A B C D (3) E F G

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Clutch
Engaged 2 1 3 - 4 5 6

Pressure Pressure Pressure Pressure Pressure Pressure Pressure

Thickness
Change Change Change Change Change Change Change
of Shim

5J-2721 Shim

See the
0.13 mm 19 kPa 20 kPa 20 kPa footnote 17 kPa 19 kPa 19 kPa
(0.005 (2.8 psi) (2.9 psi) (2.9 psi) below. (3) (2.5 psi) (2.7 psi) (2.8 psi)
inch)

6J-3993 Shim

See the
0.25 mm 39 kPa 41 kPa 41 kPa footnote 35 kPa 37 kPa 39 kPa
(0.010 (5.6 psi) (5.9 psi) (5.9 psi) below. (3) (5.1 psi) (5.3 psi) (5.6 psi)
inch)

4M-1751 Spacer
See the
0.41 mm 62 kPa 65 kPa 65 kPa footnote 56 kPa 59 kPa 62 kPa
(0.016 (9.0 psi) (9.4 psi) (9.4 psi) below (3). (8.1 psi) (8.6 psi) (9.0 psi)
inch)

5J-1036 Shim

See the
0.80 mm 120 kPa 125 kPa 125 kPa footnote 109 kPa 114 kPa 120 kPa
(0.031 (17.4 psi) (18.2 psi) (18.2 psi) below (3). (15.8 psi) (16.6 psi) (17.4 psi)
inch)
(1)
Do not change the amount of shims unless you are adjusting the primary pressure of the transmission clutches.
(2)
Station "H" is not used.
(3)
Station "D" does not control a clutch. When the lockup clutch solenoid is activated, Station "D" reduces the
pressure setting of the dual stage relief valve. The action of Station "D" on the ICM transmission hydraulic
control maintains the oil in the clutch supply rail at a reduced pressure. Refer to the Testing and Adjusting,
"Transmission Hydraulic Control (Pressure Pack) - Test and Adjust" for the proper procedure to adjust Station
"D".

Use Illustration 4 and Table 3 for the following problems.

Problem: The pressure at one clutch is 0 kPa (0 psi).

Probable Cause

• Selector piston plug (6) is not installed.

• The selector piston (7) is stuck.

• The modulation reduction valve (2) is stuck.

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Problem: The primary pressure is correct, but the maximum pressure is not
correct.
Probable Cause

• Incorrect inner spring (9) and/or outer spring (10) .

• Inner spring (9) is weak or broken, and/or outer spring (10) is weak or broken.

• Other components are incorrect.

Problem: The primary pressures at all the clutches are 0 kPa (0 psi).

Probable Cause

The probable cause is the pilot pressure. Perform the procedure in Testing and Adjusting,
"Transmission Hydraulic Control (Pressure Pack) - Test and Adjust".

Also refer to the Testing and Adjusting, "Transmission Hydraulic Control Pilot Pressure - Test"
for the procedure to check the pilot pressure in the ICM transmission hydraulic control.

Problem: The primary pressures at all the clutches are too low.
Probable Cause

• Weak inner springs (9) and/or outer springs (10) in all of the clutch stations

Problem: The primary pressure at one clutch is too low.

Probable Cause

• Selector piston (7) is stuck.

• Inner spring (9) is weak or broken, and/or outer spring (10) is weak or broken.

• Incorrect inner spring (9) and/or outer spring (10) .

• The primary pressure is set incorrectly. Add shims (5). Refer to Table 3.

• The housing of the clutch station is worn.

Problem: The primary pressure at one clutch is too high.

Probable Cause

• Incorrect inner spring (9) and/or outer spring (10) .

• The primary pressure is set incorrectly. Remove shims (5). Refer to Table 3.

Problem: An additional clutch receives pressure oil in certain speeds.

Probable Cause

• Decay orifice (4) is plugged.

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• The drain orifice in the return end of the rotary selector spool is plugged.

• A selector piston (7) is stuck.

• A load piston (8) is stuck.

• A modulation reduction valve (2) is stuck.

Problem: The pressure in one clutch at the high idle rpm is not correct, but the
primary pressure in the same clutch is correct.
Probable Cause

• Wrong inner spring (9) and/or outer spring (10) is installed in the load piston.

• Inner spring (9) and/or outer spring (10) in the load piston is weak or broken.

• Load piston orifice (3) is plugged.

Problem: The primary pressure in one clutch is not correct, but the pressure in
the same clutch at the high idle rpm is correct.
Probable Cause

Wrong inner spring (9) and/or outer spring (10) is installed in the load piston.

Copyright 1993 - 2011 Caterpillar Inc. Mon Feb 21 09:30:09 EST 2011
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Red privada para licenciados del SIS.

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