Professional Documents
Culture Documents
Page 1 of 43
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.
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 2 of 43
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.
5. Fully lift the body and install the two pins at the rear of the truck.
6. Disconnect the hoist control linkage as shown. Remove the cotter pin and pin that connects the rod
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 3 of 43
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:
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 4 of 43
*
To save time on tests, use the quantity of gauges and fittings that follow:
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 5 of 43
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 6 of 43
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 7 of 43
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 8 of 43
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 9 of 43
Location Of Components
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 10 of 43
(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.
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 11 of 43
(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.
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 12 of 43
(L) Pressure tap for pump. (M) Pressure tap for pilot oil.
Visual Checks
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.).
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 13 of 43
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.
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:
Probable Cause:
Problem 2:
Probable Cause:
Do Visual Check 2.
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 14 of 43
Problem 4:
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:
Probable Cause:
a. Seal failure.
b. Hose failure.
Problem 2:
Probable Cause:
Check 4:
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 15 of 43
Problem 1:
Probable Cause:
a. Seal failure.
b. Hose failure.
Problem 2:
Probable Cause:
Problem 3:
Probable Cause:
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 16 of 43
Problem 4:
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.
Problem 1:
More than 26 liters (7 U.S. gal) of oil is drained from the transmission and transfer gears.
Probable Cause:
Problem 2:
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 17 of 43
Probable Cause:
Seal failure.
Problem 3:
Probable Cause:
Problem 4:
Probable Cause:
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).
Problem 1:
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 18 of 43
Probable Cause:
a. Seal failure.
b. Hose failure.
Problem 2:
Probable Cause:
Problem 3:
Probable Cause:
Problem 4:
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.
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 19 of 43
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.
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 20 of 43
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.
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 21 of 43
Selector Group
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 22 of 43
Problem 1:
Probable Cause:
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:
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.
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 23 of 43
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.
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:
b. Too much leakage in the transmission lubrication circuit (bad seals, etc.).
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 24 of 43
Selector Valve
Problem 2:
Probable Cause:
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 25 of 43
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.
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.
7. Start and run the engine at LOW IDLE rpm in NEUTRAL. Keep the parking brakes engaged.
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 26 of 43
Selector Group
(4) Priority reduction valve. (5) Rotary selector spool. (6) Screen. (7) Spacers. (8) Neutralizer valve.
(M) Pressure tap for pilot oil.
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 27 of 43
Problem 1:
Probable Cause:
The setting of priority reduction valve (4) is too low. Add spacers (7), see Spacer Chart for Priority
Reduction Valve.
Problem 2:
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.
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 28 of 43
Problem 4:
The pressure on the gauge is correct, but the pressures at ALL clutches are too low (Test 4).
Probable Cause:
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.
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 29 of 43
5. Disconnect the hoist control linkage. Remove the cotter pin and pin that connects the rod to the
hoist control lever.
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.
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.
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 30 of 43
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.
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 31 of 43
(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.
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.
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 32 of 43
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.
(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).
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 33 of 43
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 34 of 43
Problem 1:
Probable Cause:
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 35 of 43
Problem 2:
Probable Cause:
Problem 3:
Probable Cause:
Problem 4:
Probable Cause:
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
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 36 of 43
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:
Problem 9:
Pressure in one clutch does not decrease rapidly or low (approximately primary) pressure remains
(stays) in one clutch.
Probable Cause:
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 37 of 43
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.
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.
6. Make a record of the pressures on the gauges. Use the Primary Clutch Pressure Measurement
chart to record measurements.
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 38 of 43
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.
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 39 of 43
(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).
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 40 of 43
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 41 of 43
Problem 1:
Probable Cause:
Problem 2:
Probable Cause:
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 42 of 43
Problem 3:
Probable Cause:
Problem 4:
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:
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:
b. Weak or broken inner spring (20) for the modulation reduction valve.
Problem 7:
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014
Copyright 1991, 2014 Caterpillar Inc. All Rights Reserved. Page 43 of 43
Pressure in one clutch at HIGH IDLE rpm is not correct, but primary pressure in the same clutch is
correct.
Probable Cause:
Problem 8:
Primary pressure in one clutch is not correct, but pressure in the same clutch at HIGH IDLE rpm is
correct.
Probable Cause:
file://C:\SIS\TMP\sis4EAA1prt.html 30/11/2014