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01X 769C TRUCK Testing & Adjusting


Media Number SENR6869-00 Publication Date 1994/07/06 Update Date 1995/12/07

Transmission Hydraulic System Troubleshooting

Make reference to the following warning and pressure tap locations for all checks and tests of the
transmission hydraulic system. If the problem area is not known, do the checks and tests in the order
they are given. For all tests, the oil must be at normal temperature of operation.

Sudden movement of the machine or release of oil under

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


To prevent possible injury, do the procedure that follows
before testing and adjusting the transmission.

1. Move the machine to a smooth horizontal location. Move away from working machines and
personnel.

2. Put the transmission shift lever in NEUTRAL position. Stop the engine.

3. Permit only one operator on the machine. Keep all other personnel either away from the machine or
in view of the operator.

4. Engage the parking brakes.

Pins Installed On Body Of Truck (Typical Example)

5. Fully lift the body and install the two pins at the rear of the truck.

Hoist Control Linkage Disconnected

6. Disconnect the hoist control linkage as shown. Remove the cotter pin and pin that connects the rod

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to the hoist control lever.

7. Make sure the transmission rotary selector spool is in NEUTRAL position.

8. Make sure all hydraulic pressure is released before any fitting, hose or component is loosened,
tightened, removed or adjusted.

Test Equipment

*
A minimum quantity of gauges and fittings needed:

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*
To save time on tests, use the quantity of gauges and fittings that follow:

Transmission Speed And Clutch Engagement

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Transmission Hydraulic Schematic

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Transmission Hydraulic System In FOURTH speed, Engine Running

(1) Charging section of transmission oil pump.

(2) Valve (oil cooler bypass).

(3) Transmission oil filter.

(4) Downshift solenoid.

(5) Upshift solenoid.

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(6) Rotary actuator.

(7) Selector piston for No. 3 clutch.

(8) Load piston for No. 3 clutch.

(9) Modulation reduction valve for No. 3 clutch.

(10) Pressure control group.

(11) Modulation reduction valve for No. 5 clutch.

(12) Load piston for No. 5 clutch.

(13) Selector piston for No. 5 clutch.

(14) Transmission oil tank.

(15) Transmission oil cooler.

(16) Scavenge section of transmission oil pump.

(17) Suction screen.

(18) Magnetic screen.

(19) Reservoir in transmission case.

(20) Modulation reduction valve for No. 4 clutch.

(21) Load piston for No. 4 clutch.

(22) Selector piston for No. 4 clutch.

(23) Priority reduction valve.

(24) Neutralizer valve.

(25) Rotary selector spool.

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(26) Selector group.

(27) Selector piston for No. 1 clutch.

(28) Load piston for No. 1 clutch.

(29) Modulation reduction valve for No. 1 clutch.

(30) Modulation reduction valve for No. 6 clutch.

(31) Load piston for No. 6 clutch.

(32) Selector piston for No. 6 clutch.

(33) Selector piston for No. 2 clutch.

(34) Load piston for No. 2 clutch.

(35) Modulation reduction valve for No. 2 clutch.

(36) Oil cooler relief valve.

(37) Modulation reduction valve for No. 7 clutch.

(38) Load piston for No. 7 clutch.

(39) Selector piston for No. 7 clutch.

(40) Relief valve.

(41) Passage for transmission lubrication.

(A) Pressure tap for No. 3 clutch.

(B) Pressure tap for No. 1 clutch.

(C) Pressure tap for No. 2 clutch.

(D) Not used.

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(E) Pressure tap for No. 5 clutch.

(F) Pressure tap for No. 4 clutch.

(G) Pressure tap for No. 6 clutch.

(H) Pressure tap for No. 7 clutch.

(J) Pressure tap for upshift pressure.

(K) Pressure tap for downshift pressure.

(L) Pressure tap for pump.

(M) Pressure tap for pilot oil.

(N) Pressure tap for transmission lubrication.

Location Of Components

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Transmission Lines And Filter

(1) Charging section of transmission oil pump. (2) Transmission oil cooler bypass valve. (3)
Transmission oil filter. (13) Torque converter and brake oil cooler. (14) Transmission oil tank (section).
(15) Magnetic screen (inside transfer gear case). (16) Scavenge section of transmission oil pump.

Pressure Tap Locations

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(A) Pressure tap for No. 3 clutch. (B) Pressure tap for No. 1 clutch. (C) Pressure tap for No. 2 clutch.
(D) Not used. (E) Pressure tap for No. 5 clutch. (F) Pressure tap for No. 4 clutch. (G) Pressure tap
for No. 6 clutch. (H) Pressure tap for No. 7 clutch. (M) Pressure tap for pilot oil.

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(L) Pressure tap for pump. (M) Pressure tap for pilot oil.

Visual Checks

Make reference to the WARNING on the first page of


Transmission Hydraulic System Troubleshooting.

Do Visual Checks first when troubleshooting a problem. Make the checks with the engine STOPPED
and the parking brakes ENGAGED. Put the transmission shift lever and transmission rotary selector
spool in NEUTRAL. During these checks, use a magnet to separate ferrous particles from non-ferrous
particles (O-ring seals, aluminum, etc.).

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Check 1:

Check the oil level in the transmission oil tank. Look for air or water in the oil (through the sight
gauge). Many problems in the transmission are caused by low oil level or air in the oil. Add oil to the
transmission oil tank if it is needed. The transmission hydraulic system uses SAE 30 oil.

Inner Right Side Of Main Frame

(1) Transmission oil filter.

NOTE: There is an oil filter bypass valve on the inlet side of the transmission oil filter. The oil filter
bypass will open and let oil bypass (go around) the oil filter element whenever the pressure difference
between inlet oil and outlet oil through the oil filter gets above 250 kPa (36 psi). Any oil that does not
go through the filter element goes directly into the hydraulic circuit. Dirty oil will cause restrictions in
valve orifices, sticking valves, etc.

Problem 1:

There is an indication of water in the oil.

Probable Cause:

Failure of the transmission oil cooler.

Problem 2:

There is an indication of air in the oil.

Probable Cause:

Do Visual Check 2.

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Problem 4:

The oil level is too low.

Probable Cause:

Do Visual Check 2.

Check 2:

Inspect all oil lines, hoses, and connections for damage or leaks. Look for oil on the ground under the
machine.

NOTE: If oil can leak out of a fitting or connection, air can leak in. Air in the system can be as bad as
not enough oil.

Check 3:

Remove and inspect (cut apart if necessary) transmission oil filter (1) for foreign material.

Problem 1:

Rubber particles are found.

Probable Cause:

a. Seal failure.

b. Hose failure.

Problem 2:

Shiny steel particles are found.

Probable Cause:

Mechanical failure of the charging section of transmission oil pump.

Check 4:

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Remove and inspect magnetic screen (2) for foreign material.

Bottom Of Transfer Gear Case

(2) Magnetic screen (behind cover).

Problem 1:

Rubber particles are found.

Probable Cause:

a. Seal failure.

b. Hose failure.

Problem 2:

Bronze particles are found.

Probable Cause:

Worn clutches in the transmission.

Problem 3:

Iron or steel chips are found.

Probable Cause:

Broken components in transfer gears or transmission.

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Problem 4:

Aluminum particles are found.

Probable Cause:

Worn housings, load pistons or selector pistons in the pressure control group.

Check 5:

Remove the plugs in the bottom of the transmission case. This will drain all of the oil out of the
transmission and transfer gears. Measure the total amount of oil removed at both plugs. Inspect the oil
for foreign material.

Drain Plugs For Transmission Case

Problem 1:

More than 26 liters (7 U.S. gal) of oil is drained from the transmission and transfer gears.

Probable Cause:

a. Restriction in magnetic screen (2).

b. Failure of the scavenge section of the transmission oil pump.

c. Too much leakage in a clutch or clutches of the transmission.

Problem 2:

Rubber particles are found.

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Probable Cause:

Seal failure.

Problem 3:

Bronze particles are found.

Probable Cause:

Worn clutches in transmission.

Problem 4:

Iron or steel chips are found.

Probable Cause:

Broken components in transmission or transfer gears.

Check 6:

Drain the oil from the transmission oil tank. Inspect the bottom of the oil tank for debris. Remove and
clean suction screen (3).

Hydraulic Oil Tank

(3) Suction screen.

Problem 1:

Rubber particles are found.

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Probable Cause:

a. Seal failure.

b. Hose failure.

Problem 2:

Shiny steel particles are found.

Probable Cause:

Mechanical failure of scavenge section of the transmission oil pump.

Problem 3:

Bronze particles are found.

Probable Cause:

Worn clutches in the transmission.

Problem 4:

Aluminum particles are found.

Probable Cause:

Worn housings, load pistons or selector pistons in the pressure control group.

NOTE: If any of the above particles are found during any Visual Check, all components of the
transmission hydraulic system must be cleaned. Do not use any damaged parts. Any damaged parts
must be removed and new parts installed.

Transmission Hydraulic System Tests

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Make reference to the WARNING on the first page of the


Transmission Hydraulic System Troubleshooting.

Test 1. Transmission Pump Pressure

This test will show if:

a. Charging section of the transmission oil pump is good.

b. Relief valve (1) is set correctly.

Procedure:

1. At pressure tap (L), use a coupler (and hose if necessary) and connect a pressure gauge [3400
kPa (580 psi)] to the nipple.

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Location Of Pressure Tap (L) For Pump (Pressure), (M) Pressure for Pilot Oil

2. With the parking brakes engaged, start and run the engine at LOW IDLE rpm in NEUTRAL. The
minimum pressure on the gauge should be 2690 kPa (390 psi).

3. Run the engine at HIGH IDLE rpm in NEUTRAL. The maximum pressure on the gauge should be
3210 kPa (465 psi).

4. When this test is complete, stop the engine and remove the test equipment.

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Selector Group

(1) Relief valve. (2) Spacers.

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Problem 1:

Oil pressure is too low.

Probable Cause:

a. Failure of charging section of transmission oil pump.

b. The setting of relief valve (1) is too low. Add spacers (2), see Spacer Chart for Relief Valve. Adjust
for LOW IDLE setting.

Problem 2:

Oil pressure is too high.

Probable Cause:

The setting of relief valve (1) is too high. Remove spacers (2), see Spacer Chart for Relief Valve.
Adjust for the LOW IDLE setting.

Test 2. Transmission Lubrication Pressure

This test will show if:

a. Oil pressure to the transmission lubrication circuit is good.

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b. Transmission lubrication relief valve (3) is closed.

Procedure:

1. At pressure tap (N), use a coupler (and hose if necessary) and connect a pressure gauge [400 kPa
(58 psi)] to the nipple.

Location Of Pressure Tap (N) For Transmission Lubrication (Typical Example)

2. With the parking brakes engaged, start and run the engine at LOW IDLE rpm in NEUTRAL. The
pressure on the gauge must be a minimum of 4 kPa (.5 psi).

3. Run the engine at HIGH IDLE rpm in NEUTRAL. The pressure on the gauge must be 165 to 235
kPa (24 to 34 psi).

4. When this test is complete, stop the engine and remove the test equipment.

Problem 1:

The transmission pump pressure is correct (Test 1). Transmission lubrication pressure is too low.

Probable Cause:

a. Transmission lubrication relief valve (3) is open.

b. Too much leakage in the transmission lubrication circuit (bad seals, etc.).

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Selector Valve

(3) Transmission lubrication relief valve.

Problem 2:

The oil gets too hot during normal operation.

Probable Cause:

Too much oil in transmission case. Do Visual Check 5.

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Test 3. Pilot Pressure

This test will show if:

The operation and setting of priority reduction valve (4) is correct.

Procedure:

NOTE: If Tests 4 and/or 5 are to be performed and FT1874 Transmission Test Cover is to be used,
perform Steps 1 through 6 and go on to the next test. Pilot pressure can be checked while clutch
pressures are checked.

1. Disconnect the wiring harness from the downshift solenoid and upshift solenoid.

2. Remove the solenoid guard and large cover from the transmission case.

3. Remove the plug from pressure tap (M).

4. Install a 3B-6552 Elbow [.125 (1/8 in) NPT] in pressure tap (M). Connect a 3B-7282 Nipple [.125
(1/8 in) NPT X 152 mm (6 in) long] with a 6V-4142 Nipple to the elbow.

5. Put the large cover back on top of the transmission case. To prevent the release (spray) of oil and
to keep dirt out, use a piece of plastic or paper along with the cover.

Alternate Step 5. Install the FT1874 Transmission Test Cover in place of large cover. Use four bolts
evenly spaced to hold cover in place.

6. Connect a pressure gauge [3400 kPa (580 psi)] to the nipple.

7. Start and run the engine at LOW IDLE rpm in NEUTRAL. Keep the parking brakes engaged.

8. The pressure on the gauge must be 1725 ± 70 kPa (250 ± 10 psi).

9. When the test is complete, stop the engine.

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Selector Group

(4) Priority reduction valve. (5) Rotary selector spool. (6) Screen. (7) Spacers. (8) Neutralizer valve.
(M) Pressure tap for pilot oil.

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Problem 1:

The pressure on the gauge is too low.

Probable Cause:

The setting of priority reduction valve (4) is too low. Add spacers (7), see Spacer Chart for Priority
Reduction Valve.

Problem 2:

The pressure on the gauge is too high.

Probable Cause:

The setting of priority reduction valve (4) is too high. Remove spacers (7). See Spacer Chart for
Priority Reduction Valve.

Problem 3:

The pressure on the gauge is correct, but the pressures at ALL clutches are 0 kPa (0 psi) (Test 4).

Probable Cause:

a. The operation of neutralizer valve (8) is not correct. Disassemble the selector group. Check for
foreign material or worn or damaged parts. Make sure the orifice and/or ball check valve of the
neutralizer valve are free of any debris.

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b. Restriction in screen (6) in rotary selector spool (5).

Problem 4:

The pressure on the gauge is correct, but the pressures at ALL clutches are too low (Test 4).

Probable Cause:

Restriction in screen (6) in rotary selector spool (5).

Test 4. Pressure Control Group Clutch Pressures

This test will show if:

a. Transmission clutch pressures are correct.

b. There is too much oil leakage in a clutch.

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, do the procedure that follows
before Tests 4 and/or 5 are done.

1. Move the machine to a smooth horizontal location. Move away from working machines and
personnel.

2. Put the transmission shift lever in NEUTRAL position. Engage the parking brake. Stop the engine.

3. Permit only one operator on the machine. Keep all other personnel either away from the machine or
in view of the operator.

4. On a truck, raise the body and install the two pins at the rear of the truck.

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5. Disconnect the hoist control linkage. Remove the cotter pin and pin that connects the rod to the
hoist control lever.

6. Make sure the transmission rotary selector spool is in NEUTRAL position.

7. Make sure all hydraulic pressure is released before any fitting, hose or component is loosened,
tightened, removed or adjusted.

8. Disconnect the rear drive shaft from the rear of the transmission.

9. Make sure the test cover is installed on the transmission case before any tests are done.

Procedure To Manually Shift The Transmission With The Engine Running (Drive Axles
Removed)

This procedure will save time when the transmission is tested. Instead of the use of the transmission
shift lever in the operator's station, shifts can be made down on the transmission.

1. Make sure the transmission shift lever is in NEUTRAL position.

2. Disconnect the wiring harness from the downshift solenoid.

Ratchet And Extension Installed In The Rotary Selector Spool

3. With the engine STOPPED, remove the plug (for the rotary selector spool) from the left side of the
transmission case.

4. Use the .25 (1/4) inch square drive extension and ratchet to turn the transmission rotary selector
spool. When the ratchet is turned clockwise as far as it will go, rotary selector spool (5) is in
NEUTRAL position. The order of detent positions from NEUTRAL is REVERSE and FIRST through
SEVENTH speeds respectively.

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Procedure:

NOTE: If FT1874 Transmission Test Cover is used, a gauge can be installed at pressure tap (M) to
check pilot pressure. If 6V-6064 Transmission Test Cover is used, make sure the plug is installed at
pressure tap (M).

1. Disconnect the wiring harness from the downshift solenoid and upshift solenoid. Remove the
solenoid guard and large cover from the top of the transmission case. Install FT1874 Transmission
Test Cover in place of the large cover. Use four bolts to hold the test cover in position.

Alternate Step 1. Remove small cover from large cover and install 6V-6064 Transmission Test Cover
in place of the small cover. Use four nuts to hold the test cover in position.

2. At pressure taps (A), (B), (C), (E), (F), (G), and (H), connect pressure gauges [3400 kPa (580 psi)]
to the nipples.

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Pressure Test Gauge Installation

(A) Pressure tap for No. 4 clutch. (B) Pressure tap for No. 2 clutch. (C) Pressure tap for No. 1 clutch.
(D) Not used. (E) Pressure tap for No. 5 clutch. (F) Pressure tap for No. 6 clutch. (G) Pressure tap
for No. 7 clutch. (H) Pressure tap for No. 3 clutch. (M) Pressure tap for pilot oil.

3. Start and run the engine at LOW IDLE rpm in NEUTRAL.

4. Make a record of the pressures on the gauges. Use the Maximum Clutch Pressure Measurement
chart to record measurements.

5. Use the .25 (1/4) inch square drive ratchet and extension. Move transmission rotary selector spool
(5) to REVERSE position.

6. Make a record of the pressures on the gauges. Use the Maximum Clutch Pressure Measurement
chart to record measurements.

7. Manually shift the transmission into all forward speeds and make a record of the pressures on the
gauges for each shift. Use the Maximum Clutch Pressure Measurement chart to record
measurements.

8. With the transmission still in FIFTH speed, increase the engine rpm to the Maximum Governor
Setting (HIGH IDLE).

9. Make a record of the pressures on the gauges. Use the Maximum Clutch Pressure Measurement
chart to record measurements.

10. Decrease engine rpm to the Minimum Governor Setting (LOW IDLE) and manually shift the
transmission to FOURTH speed. Increase engine rpm again to the Maximum Governor Setting. Make
a record of the pressures on the gauges. Use the Maximum Clutch Pressure Measurement chart to
record measurements.

11. Do Step 10 again in all speeds including REVERSE and NEUTRAL. Make sure to decrease
engine rpm before each downshift is made.

12. Stop the engine with the transmission rotary selector spool in NEUTRAL.

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13. Make a comparison of the actual clutch pressures recorded on the Maximum Clutch Pressure
Measurement chart, with the specifications given in the Maximum Clutch Pressure Specifications chart.

14. After the problem is corrected, remove the test equipment.

Pressure Control Group

(9), (10), (11), (12), (13), (14) and (15) Modulation reduction valves. (16) Selector piston plugs
(seven). (17) Load piston orifice (seven). (18) Decay orifice plug (six). (19) Load piston plug (seven).
(20) Spring [inner (seven)]. (21) Spring [outer (seven)]. (22) Shims (seven places). (A), (B), (C), (D),
(E), (F), (G) and (H) Pressure taps (also load piston body identification).

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Problem 1:

Pressures at ALL clutches are 0 kPa (0 psi).

Probable Cause:

Pilot pressure. Do Test 3.

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Problem 2:

Pressures at ALL clutches are too low.

Probable Cause:

Pilot pressure. Do Test 3.

Problem 3:

Pressure at ONE clutch is 0 kPa (0 psi).

Probable Cause:

Selector piston plug (16) is not installed.

Problem 4:

Pressure in a clutch does not increase above primary pressure.

Probable Cause:

a. Load piston plug (19) not installed.

b. Load piston orifice (17) is plugged.

c. Broken spring(s) (20, 21) in the modulation reduction valve.

Problem 5:

An additional clutch gets pressure oil in some speeds (too many clutches are engaged).

Probable Cause:

Do Test 5.

Problem 6:

Pressure in one clutch at HIGH IDLE rpm is not correct, but primary pressure in the same clutch is

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correct.

Probable Cause:

Do Test 5.

Problem 7:

Primary pressure in one clutch is not correct, but pressure in the same clutch at HIGH IDLE rpm is
correct.

Probable Cause:

Do Test 5.

Problem 8:

Pressure in one clutch at HIGH IDLE rpm is correct, but pressure in the same clutch at LOW IDLE rpm
is not correct (too low).

Probable Cause:

Bad seals in a clutch of the transmission.

Problem 9:

Pressure in one clutch does not decrease rapidly or low (approximately primary) pressure remains
(stays) in one clutch.

Probable Cause:

a. Decay orifice (18) is plugged.

b. Drain orifice in rotary selector spool (5) is plugged.

Test 5. Primary Clutch Pressures

This test will show if:

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The clutch pressures are adjusted correctly.

Make reference to the WARNING given in Test 4.

Procedure:

NOTE: Use the Procedure To Manually Shift The Transmission With The Engine Running (Drive Axles
Removed) given in Test 4.

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

1. If 6V-6064 Transmission Test Cover is used, remove small cover from the top of the transmission
case. If FT1874 Transmission Test Cover is used, remove the large cover from the transmission case.

2. Remove seven load piston plugs (19) from their bodies.

3. Put the test cover back in position and install four bolts to hold it in place.

4. At pressure taps (A), (B), (C), (E), (F), (G) and (H), connect pressure gauges [1000 kPa (145 psi)]
to the nipples.

5. Start and run the engine at LOW IDLE rpm in NEUTRAL.

6. Make a record of the pressures on the gauges. Use the Primary Clutch Pressure Measurement
chart to record measurements.

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7. Use the .25 (1/4) inch square drive ratchet and extension. Move the transmission rotary selector
spool to REVERSE position.

8. Make a record of the pressures on the gauges. Use the Primary Clutch Pressure Measurement
chart to record measurements.

9. Manually shift the transmission into and all forward speeds and make a record of the pressures on
the gauges for each shift.

10. Stop the engine with the transmission rotary selector spool in NEUTRAL.

11. Make a comparison of the actual primary clutch pressure, recorded on the Primary Clutch
Pressure Measurement chart and the specification for each clutch given in the Primary Clutch Pressure
Specifications chart.

12. After the problem is corrected, remove the pressure gauges and test cover. Install load piston
plugs (19).

13. Install large cover, small cover and the solenoid guard. Connect the wiring harness to the
solenoids.

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Pressure Control Group

(9), (10), (11), (12), (13), (14) and (15) Modulation reduction valves. (16) Selector piston plugs
(seven). (17) Load piston orifice (seven). (18) Decay orifice plug (six). (19) Load piston plug (seven).
(20) Spring [inner (seven)]. (21) Spring [outer (seven)]. (22) Shims (seven places). (A), (B), (C), (D),
(E), (F), (G) and (H) Pressure taps (also load piston body identification).

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Problem 1:

Pressure at one clutch is 0 kPa (0 psi).

Probable Cause:

Selector piston plug (16) is not installed.

Problem 2:

Primary pressures at all clutches are 0 kPa (0 psi).

Probable Cause:

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Pilot pressure. Do Test 3.

Problem 3:

Primary pressures at all clutches are too low.

Probable Cause:

Pilot pressure. Do Test 3.

Problem 4:

Primary pressure at one clutch is too low.

Probable Cause:

Add shims (22) for the modulation reduction valve of the clutch that has low pressure. See Shim Chart
for Pressure Control Group.

Problem 5:

Primary pressure at ONE clutch is too high.

Probable Cause:

Remove shims (22) for the modulation reduction valve that has high pressure. See Shim Chart For
Pressure Control Group.

Problem 6:

An additional clutch gets pressure oil in some speeds (too many clutches are engaged).

Probable Cause:

a. A selector piston is stuck (will not go back to its original position).

b. Weak or broken inner spring (20) for the modulation reduction valve.

Problem 7:

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Pressure in one clutch at HIGH IDLE rpm is not correct, but primary pressure in the same clutch is
correct.

Probable Cause:

a. Wrong outer spring(s) (21) installed in the modulation reduction valve.

b. Weak or broken outer spring(s) (21) in the modulation reduction valve.

c. Load piston orifice (17) is plugged.

Problem 8:

Primary pressure in one clutch is not correct, but pressure in the same clutch at HIGH IDLE rpm is
correct.

Probable Cause:

a. Wrong outer spring(s) (21) installed in the modulation relief valve.

Copyright 1991, 2014 Caterpillar Inc.


All Rights Reserved.

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