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Producto: TRUCK
Modelo: 789C TRUCK 2BW
Configuracin: 789C Truck 3516 Engine 2BW00001-UP (MACHINE)

Pruebas y Ajustes
789C Off-Highway Truck Power Train
Nmero de medio -SENR1523-04

Fecha de publicacin -01/06/2004

Fecha de actualizacin -11/06/2004

i01410307

Transmission Hydraulic Control Primary Clutch Pressure - Test and

Adjust
SMCS - 3073
Table 1
Tools Needed
Part Number

Part Description

Qty

8T-5200

Generator and Counter Signal Group

6V-6064

Transmission Test Cover (1)

FT-1775

Transmission Test Cover (1)

Pressure Gauge
8T-0854

1
0 to 1000 kPa (0 to 150 psi)

(1)

177-7862

Hose Assembly

6V-4143

Coupler

12

9S-1721

Socket Extension

9U-6635

Ratchet

Only one type of transmission test cover is necessary.

Note: An 8T-5200 Signal Generator/Counter can be used to shift the transmission during the diagnostic tests
instead of manual shifting.
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.
This test will determine if the clutch pressures are correctly adjusted.

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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.

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 machine.
Note: Failure to perform Step 1 can result in damage to the transmission clutches.
2. If a 6V-6064 Transmission Test Cover is used, remove the large cover from the top of the transmission case.
If a FT1775 Transmission Test Cover is used, remove the smaller cover from the transmission case.
3. Remove six load piston plugs (33) .
4. Reinstall the test cover. Install four bolts in order to hold the test cover in place.

Illustration 1

g00398738

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
(D) Pressure tap for the signal pressure for the dual stage relief valve
(E) Pressure tap for the No. 4 clutch

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(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. Install two 6V-4143 Couplers, 177-7862 Hose Assembly and 8T-0854 Pressure Gauge 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 3 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. Refer to the procedure for manual shifts in
the Testing and Adjusting, "Transmission Hydraulic Control Clutch Pressure - Test".
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 3 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 3 and the pressure for each clutch that
is provided in Table 3.
13. After the pressures are correctly set, remove the pressure gauges and the test cover. Install load piston plugs
(33) .
14. Install the large cover, the small cover, and the solenoid guard. Connect the wiring harness to the solenoids.
Note: After the primary pressures are set, the maximum clutch pressures must be set. Perform the Testing
and Adjusting, "Transmission Hydraulic Control Clutch Pressure - Test".
15. Install the drive axles on the machine or install the drive shaft from the machine.
Table 2
Speed

N-1

N-2

Engaged
Clutches

1, 6

1, 5

2, 5

1, 4

2, 4

1, 3

2, 3

Stations

"C"

"B"

"B", "G"

"B", "F"

"A", "F"

"B ", "E"

"A", "E"

"B", "C"

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"A", "C"

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Table 3
Measurements of the Primary Clutch Pressure
Station (1)
Low Idle
Pressure (3)

"A"

"B"

"C"

525 kPa
(76.1 psi)

475 kPa
(68.9 psi)

480 kPa
(69.6 psi)

"D" (2)

"E"

"F"

"G"

425 kPa
(61.6 psi)

450 kPa
(65.3 psi)

425 kPa
(61.6 psi)

N/A

Actual

N/A

(1)

Station "H" is not used.

(2)

Station "D" does not control a clutch. Station "D" controls the dual stage relief valve for the system pressure.

(3)

The tolerance is +50 - 35 (+7 - 5).

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Illustration 2

g00485627

Pressure control valve

(28) Modulation reduction valves (seven)
(29) Selector piston plugs (seven)
(30) Load piston orifice
(31) Decay orifice plugs (five)
(32) Shims (seven places)
(33) Load piston plugs (six)

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(34) Inner springs (six)
(35) Outer springs (seven)
(36) Load piston
(37) Selector piston

Table 4
Specifications and Identification of the Components of the Pressure Control Valve
Location of the Load
Piston Body (1)

4.58 mm
(.180 inch)

2.54 mm
(.100 inch)

2.54 mm
(.100 inch)

2.54 inch
(.100 inch)

6.60 mm
6.60 mm
(0.260 inch) (.260 inch)

Color of the Outer

Spring of the Load
Piston

Light green
color

Yellow
color

Light green
color

Light green
color

Light green
color

Light
green
color

Color of the Inner

Spring of the Load
Piston

Light blue
color

Light blue
color

Light blue
color

Orange
color

Yellow
color

Light
green
color

Size of the Decay

Orifice

1.40 mm
(0.055 inch)

1.57 mm
(0.062 inch)

1.98 mm
(0.078
inch)

1.57 mm
(0.062 inch)

1.40 mm
(0.055 inch)

Color of the Decay

Orifice

Yellow
color

Green color

Red color

Green color

Yellow
color

Thickness of the
Load Piston Orifice

(1)

The location of the load piston body is identical to the location of the station for the valve. Station "H" is not used.

Table 5
(1) Shims for the Pressure Control Valve
Pressure Change per Shim
Station (1)
Engaged
Clutch
Thickness of
Shim

D (2)

Pressure
Change

Pressure
Change

Pressure
Change

Pressure
Change

Pressure
Change

Pressure
Change

Pressure
Change

17 kPa (2.5
psi)

19 kPa (2.7
psi)

19 kPa (2.8
psi)

5J-2721 Shim
0.13 mm
(0.005 inch)

20 kPa (2.9
psi)

17 kPa (2.4
psi)

20 kPa (2.9
psi)

12 kPa (1.7
psi)

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6J-3993 Shim
0.25 mm
(0.010 inch)

41 kPa (5.9
psi)

33 kPa (4.8
psi)

41 kPa (5.9
psi)

25 kPa (3.6
psi)

35 kPa (5.1
psi)

37 kPa (5.4
psi)

39 kPa (5.6
psi)

56 kPa (8.1
psi)

59 kPa (8.6
psi)

62 kPa (9.0
psi)

109 kPa
(15.8 psi)

114 kPa
(16.6 psi)

120 kPa
(17.4 psi)

4M-1751 Spacer
0.41 mm
(0.016 inch)

65 kPa (9.4
psi)

53 kPa (7.7
psi)

65 kPa (9.4
psi)

39 kPa (5.7
psi)

5J-1036 Shim
0.80 mm
(0.031 inch)

125 kPa
(18.2 psi)

103 kPa
(15.0 psi)

125 kPa
(18.2 psi)

76 kPa
(11.0 psi)

(1)

Station "H" is not used.

(2)

Station "D" does not control a clutch. Station "D" controls the dual stage relief valve for the system pressure.

Problem: The primary pressure is correct, but the maximum pressure is

not correct.
Probable Cause
The load piston springs (34) and (35) are weak or incorrect. Replace the load piston springs.

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

Probable Cause

Selector piston plug (29) is not installed.

The selector piston (37) is stuck.

The modulation reduction valve (28) is stuck.

Problem: The primary pressures at all the clutches are 0 kPa (0 psi).
Probable Cause
The probable cause is the pilot pressure. Perform the test in the Testing and Adjusting, "Transmission Hydraulic
Control Pilot Pressure - Test and Adjust".

Problem: The primary pressures at all the clutches are too low.
Probable Cause
The probable cause is the pressure for the transmission charging pump section of the transmission gear pump.
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Perform the test in the Testing and Adjusting, "Gear Pump (Transmission Charging) Pressure - Test and Adjust".

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

Probable Cause

Selector piston (37) is stuck.

Inner spring (34) is weak or broken, and/or outer spring (35) is weak or broken.

Incorrect inner spring (34) and/or outer spring (35) .

The primary pressure is set incorrectly. Add shims (32). Refer to Table 5.

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

Probable Cause

Incorrect inner spring (34) and/or outer spring (35) .

The primary pressure is set incorrectly. Remove shims (32). Refer to Table 5.

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

Probable Cause

Decay orifice (31) is plugged.

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

A selector piston (37) is stuck.

A load piston (36) is stuck.

A modulation reduction valve (28) 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 (34) and/or outer spring (35) is installed in the load piston.

Inner spring (34) and/or outer spring (35) in the load piston is weak or broken.

Load piston orifice (30) 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
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Wrong inner spring (34) and/or outer spring (35) is installed in the load piston.

Copyright 1993 - 2009 Caterpillar Inc.

Todos los derechos reservados.
Red privada para licenciados del SIS.

Fri Apr 24 17:24:02 UTC-0400 2009

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