Testing and Adjusting

980G Series II Wheel Loader Power Train

Media Number -RENR6008-02 Publication Date -01/01/2004 Date Updated -07/01/2004

   
i01919881

Transmission Pressures - Test and Adjust

SMCS - 3030-025; 3030-081

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. Shift the rocker switch for the transmission direction control to the NEUTRAL
position.

3. Lower the work tool to the ground.

4. Engage the parking brake.

5. Place blocks in front of the wheels and behind the wheels.

6. Install the steering frame lock.

7. Remove the front axle shafts and rear axle shafts except for stall tests.
 8. Allow only authorized personnel on the machine. Keep unauthorized personnel
off the machine and in 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  

Diagnostic Testing of the Transmission Electronic

Control
The electronic control module (ECM) for the transmission is located below the floor
panel at the right rear of the cab. The main function of the ECM is shifting the
transmission. The ECM receives information from the transmission controls and the
auto/manual switch in order to shift the transmission to the desired speed and direction.

The ECM also controls the starting of the engine and the backup alarm. The ECM will
not allow the engine to be started unless the direction control switch is in the
NEUTRAL position. The backup alarm is activated when the direction control switch is
in the REVERSE position.

The ECM has a built-in diagnostic system in order to detect faults in the electronic
system of the transmission. The diagnostic information is displayed on the electronic
display module, when the system is placed in the service mode. For information about
system operation and testing and adjusting, refer to Service Manual, "Electronic
Transmission Control System".

Test Procedures

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 g00286809
Illustration 1

Transmission Hydraulic Control in the NEUTRAL position and with the Engine Stopped.

(1) Clutch solenoid valve for the Number 2 clutch

(2) Clutch solenoid valve for the Number 3 clutch

(3) Oil cooler

(4) Transmission lubrication passage

(5) Clutch solenoid valve for the Number 6 clutch

(6) Clutch solenoid valve for the Number 1 clutch

(7) Clutch solenoid valve for the Number 5 clutch

(8) Clutch solenoid valve for the Number 4 clutch

(9) Torque converter outlet relief valve

(10) Torque converter housing

(11) Flow control orifice

(12) Torque converter

(13) Converter inlet ratio valve

(14) Slug

(15) Slug

(16) Modulating relief valve

(17) Direction selector spool

(18) Transmission oil filter

(19) Second speed and fourth speed selector spool

(20) Oil pump

(21) Pressure differential valve

(22) Load piston

(23) Orifice

(24) First speed and third speed selector spool

(25) Suction screen and magnet

(26) Reservoir

(A) Transmission lubrication pressure tap

(B) Torque converter outlet pressure tap

(C) P3 Torque converter inlet pressure tap

(D) P1 Speed clutch pressure tap

(E) Pump pressure tap

(F) P2 Directional clutch pressure tap

Table 2

Transmission Pressures (1)    

Position of Governor Control Lever    

Pressure
Pressure     Pressure at Low Pressure at High Adjustment    
Tap    
Idle Idle (2)    

This pressure is
Transmission 379 to 448 kPa (55
Lubrication Oil to 65 psi) at 2100
This pressure is a
(1AY1-UP,, rpm. The
(A)     minimum of -  
7WY1-UP,, transmission is in
21 kPa (3 psi).    
B6E1-UP, and, THIRD speed and
1RY1-UP)     in NEUTRAL
position.    

This pressure is
145 to 179 kPa (21
to 26 psi) at 2100
Transmission This pressure is a
rpm. The
Lubrication Oil (A)     minimum of -  
transmission is in
(1WY1-UP)     7 kPa (1 psi).    
THIRD speed and
in NEUTRAL
position.    

This pressure is a
minimum of
380 kPa (55 psi)
and a maximum of
Add spacers
620 kPa (90 psi).
Converter Outlet (28) or remove
(B)     -   The transmission
Pressure     spacers
is in THIRD speed
(28) . (3)    
and in
FORWARD
position. The
torque converter is
in a stall condition.

Converter Inlet (C)     -   This pressure is a -  

 maximum of
980 kPa (142 psi)
with cold oil.
This pressure is a
Pressure "P3"     maximum of
827 kPa (120 psi)
with oil at normal
operating
temperature.    

This pressure is
This pressure is
379 ± 55 kPa (55
379 ± 55 kPa (55 ±
± 5 psi) lower than
5 psi) lower than
the speed clutch
Direction Clutch the speed clutch
(D)     pressure at -  
"P2"     pressure at pressure
pressure tap (F).
tap (F). Plug (H) for
Plug (H) for the
the load piston is
load piston is
installed.    
installed.    

This pressure is
69 to 207 kPa (10
Oil Pump     (E)     -   -  
to 30 psi) higher
than "P1" pressure.

The pressure is
522 ± 35 kPa (76 ±
5 psi) when the
direction switch is Add spacers
Speed Clutch
in the NEUTRAL (29) or remove
"P1" (Initial (F)     -  
position and FIRST spacers
Pressure)    
speed is selected. (29) . (3)    
Plug (H) for the
load piston is
removed.    

This pressure is a
minimum of
This pressure must 2450 kPa (355 psi)
not be less than and a maximum of
2205 kPa (320 psi)
with the 2650 kPa (384 psi)
Speed Clutch
(F)     transmission in with the -  
"P1"    
THIRD speed and transmission in
in NEUTRAL. Plug THIRD speed and
(H) for the load in NEUTRAL.
piston is installed.   Plug (H) for the
load piston is
installed.    
( 1 )
This data is taken when the following conditions are met: oil at normal operating temperature, parking
 brake engaged and installed axle shafts.
( 2 )
The data in this column is taken with the engine at high idle. The transmission lubrication pressure is
not taken with the engine at high idle.
( 3 )
Refer to Table 3.

Pressure Tap Locations

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g00287064
Illustration 2
Transmission

(A) Transmission lubrication pressure tap. (D) Direction clutch pressure tap "P2". (F) Speed clutch
pressure tap "P1". (G) Access plug for load piston plug.

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 g00287155
Illustration 3
Transmission Control Valve

(C) Converter inlet pressure tap "P3". (D) Direction clutch pressure tap "P2". (F) Speed clutch pressure tap
"P1". (G) Access plug for load piston plug.

Removal Procedure For Load Piston Plug

1. Turn the engine start switch to the OFF position.

2. Remove access plug (G) .

3. Install a 5/16-18 bolt into the end of load piston plug (H). Remove the plug.

4. Install access plug (G) .

Installation Procedure For Load Piston Plug

1. Turn the engine start switch to the OFF position.

2. Remove access plug (G) .

3. Install a 5/16-18 bolt into the end of load piston plug (H). Remove the bolt.
 Note: Verify that the O-ring is installed on plug (H) and that the seal is in good
condition.

4. Install access plug (G) .

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g00287162
Illustration 4

Relief Valve

(B) Torque converter outlet pressure tap.

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g00287163
Illustration 5

Transmission Control Valve

(C) Torque converter inlet pressure tap "P3".

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 g00287165
Illustration 6
Transmission Oil Filter

(E) Pressure tap for transmission oil pump.

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g00287171
Illustration 7
Torque Converter Outlet Relief Valve

(9) Relief valve body. (27) Relief valve. (28) Spacers.

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 g00287176
Illustration 8
Transmission Selector and Pressure Control Valve

(22) Load piston. (29) Spacers.

Table 3

Spacers    

Pressure Change for the Valve (1)    

Description     Thickness     Pressure Change Location of Spacers

4M-1751 Spacer (28)

0.40 mm (.016 inch) 19 kPa (2.7 psi)    
Outlet relief valve (9)
5S-7001 Spacer (28)    
0.90 mm (.035 inch) 40 kPa (6.0 psi)    

Load Piston (20)    

5M-9622 Spacer (29)
1.58 mm (.062 inch) 98 kPa (14.2 psi)    

5M-9623 Spacer (29)

0.91 mm (.036 inch) 57 kPa (8.20 psi)    

5M-9624 Spacer (29)

 0.25 mm (.010 inch) 16 kPa (2.29 psi)    
( 1 )
Result of the addition of one spacer or the removal of one spacer to the valve.
Table 4

Speed Range and Direction     Engaged Clutches and Energized Solenoids    

Fourth Speed Forward     3 and 2    

Third Speed Forward     4 and 2    

Second Speed Forward     5 and 2    

First Speed Forward     6 and 2    

Neutral     3  

First Speed Reverse     6 and 1    

Second Speed Reverse     5 and 1    

Third Speed Reverse     4 and 1    

Fourth Speed Reverse     3 and 1