- Integrated Toolcarrier:
- IT38G Series II (S/N: JAN1-UP; CSX1-UP)
- IT38H (S/N: JNJ1-UP)
- Wheel Loader:
- 938G Series II (S/N: RTB1-UP; CRD1-UP; PHN1-UP; B9Y1-UP)
- 938H (S/N: MCC1-UP; MJC1-UP; JKM1-UP; LKM1-UP)
Introduction
| Revision | Summary of Changes in REHS2230 |
| 03 | Standardized. |
| 02 | Added new introduction and Canceled Part Numbers section, and improved graphic. |
© 2015 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.
This special instruction contains the necessary information that is required to bench test a specific transmission arrangement. Refer to Table 2 for the correct arrangements. Bench testing the transmission ensures correct assembly and operation of the component. Rotating a transmission provides the most conclusive evaluation. Testing allows the dealer to ensure that the transmission will operate properly in the machine. The specifications in this guideline are specific to bench testing the component. Every effort has been made in order to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This guideline must be used with the latest technical information that is available from Caterpillar.
For questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. In order to address an urgent issue, use the following resources in order to communicate your request to Caterpillar Repair Process Engineering:
- Caterpillar Dealer Technical Communicator
- Dealer Solution Network
- Caterpillar Technical Representative
- Knowledge Network
| Machine Model | Transmission Arrangement |
| 938H | 252-5135 |
| IT38H | 252-5135 |
| 938G Series 2 | 201-3265 |
| IT38G Series 2 | 201-3265 |
Canceled Part Numbers and Replaced Part Numbers
This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.
Important Safety Information
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| Illustration 1 | g02139237 |
Follow all safety warnings. Most accidents that involve product operation, maintenance, or repair are caused by failure to observe safety warnings. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. Personnel must be properly trained in order to perform maintenance, repair, or operate any machine. Safety precautions and warnings are provided this instruction and on Caterpillar products. These warnings should be observed before performing any procedures. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are not all inclusive.
The hazards are identified by the "Safety Alert Symbol" which is followed by a "Signal Word" such as "DANGER", "WARNING, or" "CAUTION". The "WARNING" Safety Alert Symbol is shown in illustration below.
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| Illustration 2 | g00008666 |
This safety alert symbol means:
Pay Attention!
Become Alert!
Your Safety is Involved.
The message that appears under the safety alert symbol explains the hazard.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.
The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.
Collecting the Test Data
Since conditions vary for each test bench, use the data that is collected from your test bench. The collected data is used to compare test results. The data should be collected and maintained by the operator.
Data from each transmission arrangement is collected and stored. Averages from each transmission arrangement are often used in order to compare values on portions of transmission tests. Always compare data that is collected from the same transmission arrangement that is being tested. Averages for the last 20 transmission arrangements should be maintained.
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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. |
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Personal injury or death can result from not following the proper procedures. To avoid the possibility of injury or death, follow the established procedure. |
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Tools Needed
Note: Pressures will be sensitive to tooling setup. The diameter of the hose, the diameter of a fitting, and additional filtering can affect pressure. The required tools that are listed in Table 3 were used to develop this test procedure.
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 1U-9585 | Mounting Block Gp | 1 |
| 1U-9584 | Rail As | 2 | |
| 4C-9998 | Bracket As | 1 | |
| 9U-6001 | Crossmember As | 1 | |
| B | 1U-5798 | Drive Adapter Gp | 1 |
| C | 1U-6698 | Adapter As (Spindle) | 1 |
| 0S-1588 | Bolt (3/8-16X1.25 inch) | 6 | |
| 5M-2894 | Hard Washer | 12 | |
| D | 1U-5999 | Spindle Gp | 1 |
| 1A-1460 | Bolt (1/2-13X2.00 inch) | 4 | |
| 3B-4508 | Lockwasher | 4 | |
| E | 1U-6721 | Adapter (Drive) | 1 |
| F | 1U-9131 | Drive Adapter (Key) (1) | 1 |
| G | 1U-9359 | Drive Adapter (2) | 1 |
| H | 1U-9722 | Load Binder As (Ratchet Type) | 3 |
| T | 1U-9037 | Adapter As (Lubrication Inlet) | 1 |
| 2N-5243 | O-Ring Seal | 1 | |
| J | 1U-6233 | Adapter As | 1 |
| 6V-3940 | Bolt (M8X1.25X25 mm) | 3 | |
| 9M-1974 | Hard Washer | 3 | |
| 5N-2918 | Fitting | 1 | |
| 5L-6669 | Reducer Bushing | 1 | |
| 140-5979 | Elbow | 1 | |
| 1U-9879 | Adapter | 1 | |
| K | 1U-9872 | 4 Bolt Flange | 1 |
| 6V-1820 | Hex Bolt (M10X1.5X30 mm) | 4 | |
| 8C-9024 | Fitting As (Plain) | 1 | |
| L | 1P-4577 | Half Flange | 2 |
| 6V-1820 | Bolt (M10X1.5X30 mm) | 4 | |
| 6V-5839 | Washer | 4 | |
| 1U-8297 | Adapter | 1 | |
| 1U-8301 | Fitting | 1 | |
| 6V-4144 | Coupler | 1 | |
| 8C-9024 | Fitting As (Plain) | 1 | |
| M | 1U-8304 | Fitting (45 Degree) | 1 |
| 9U-7444 | Adapter As | 1 | |
| 8C-3206 | Half Flange | 2 | |
| 8C-9024 | Fitting As (Plain) | 1 | |
| 6V-3965 | Fitting As (Quick Disconnect) | 1 | |
| 3J-1907 | O-Ring Seal | 1 | |
| 6V-1820 | Bolt (M10X1.5X30 mm) | 4 | |
| 6V-5839 | Washer | 4 | |
| N | 8C-9024 | Fitting As (Plain) | 1 |
| 8C-9025 | Quick Coupler | 1 | |
| 3B-7749 | Fitting | 1 | |
| 120-6843 | Ball Valve | 1 | |
| U | 1P-4577 | Half Flange | 2 |
| 6V-1820 | Bolt (M10X1.5X30 mm) | 4 | |
| 6V-5839 | Washer | 4 | |
| 1U-8297 | Adapter | 1 | |
| 1U-8301 | Fitting | 1 | |
| 6V-4144 | Coupler | 1 | |
| 8C-9024 | Fitting As (Plain) | 1 | |
| P | 9U-7500 | Transmission Analyzer Tool Gp | 1 |
| OR | |||
| 277-2362 | Transmission Analyzer III Gp | 1 | |
| 306-0397 | Extension Cable | 1 | |
| 9U-7497 | Adapter Cable As | 1 | |
| Q | 146-4080 | Digital Multimeter | 1 |
| 186-3736 | Connector Socket | 2 | |
| 5P-5677 | Electrical Wire | 1 | |
| 155-2270 | Connecting Plug Kit | 1 | |
| Plug Assembly (Double Banana) (3) | 7 | ||
| R | 8T-0862 | Pressure Gauge (-100 to 500 kPa (-15 to 72 psi)) | 1 |
| 6V-4144 | Coupler | 1 | |
| S | 8T-0855 | Pressure Gauge (0 to 4,000 kPa (0 to 580 psi)) | 3 |
| 6V-4144 | Coupler | 3 | |
| ( 1 ) | This drive adapter is used with the small drive shaft. |
| ( 2 ) | This drive adapter is used with the large drive shaft. |
| ( 3 ) | Pomona Model 1330-0 |
Installation Process
- Install Tooling (A) on the test bench.
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| Illustration 3 | g03876240 |
- Use a hoist to install the transmission to Tooling (A). The weight of the transmission is approximately 907 kg (2000 lb).
 | |
| Illustration 4 | g01065836 |
- Remove threaded plug (1), if necessary.
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| Illustration 5 | g01038938 |
- Remove drain plug (2) .
 | |
| Illustration 6 | g01038939 |
- Use the mounting locations.
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| Illustration 7 | g01038941 |
 | |
| Illustration 8 | g01038943 |
- Install Tooling (B) on the torque converter.
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| Illustration 9 | g01038945 |
- Install Tooling (C) to the transmission case.
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| Illustration 10 | g01038946 |
- Install Tooling (D) to Tooling (C) .
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| Illustration 11 | g01038947 |
Note: Refer to Special Instruction, SEHS8763, "Assembly and Operation of 1U-5999 Spindle Group Used for Testing Transmissions on Hydraulic Test Bench" for additional information.
- Tighten the collet on Tooling (D) to connect Tooling (D) to Tooling (B) .
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| Illustration 12 | g01038948 |
- Install Tooling (E) to Tooling (D) .
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| Illustration 13 | g01038950 |
- Install Tooling (F) to Tooling (E) .
Note: Tooling (F) will adapt to the small drive shaft. If you are using the large drive shaft, install Tooling (G) on Tooling (F) .
 | |
| Illustration 14 | g01038951 |
- Align the transmission with the drive shaft.
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| Illustration 15 | g01038952 |
- Connect the drive shaft to Tooling (F) .
- Install the drive shaft guard.
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| Illustration 16 | g01038953 |
- Tighten all four castle nuts and jack bolts.
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| Illustration 17 | g03802221 |
- Install Tooling (H) to the output end of the transmission.
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| Illustration 18 | g01038955 |
- Install Tooling (H) to the input end of the transmission.
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| Illustration 19 | g01038956 |
- Remove cover (3) and cover (4) .
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| Illustration 20 | g01038957 |
- Remove cover (5) .
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| Illustration 21 | g01038958 |
- Remove magnetic filter (6) .
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| Illustration 22 | g01038959 |
- Install Tooling (T). Orient the slot in an upward position.
Note: Tooling (T) will divert oil to the suction side of the transmission pump. Also, Tooling (T) will prevent oil from filling the oil pan.
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| Illustration 23 | g03876250 |
- Install Tooling (J) .
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| Illustration 24 | g01038962 |
- Install Tooling (K) .
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| Illustration 25 | g02627103 |
- Install Tooling (L) .
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| Illustration 26 | g01040371 |
- Install Tooling (M) .
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| Illustration 27 | g01069600 |
- Connect Tooling (N) to Tooling (M) .
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| Illustration 28 | g01069606 |
- Install Tooling (U) .
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| Illustration 29 | g03876255 |
- Connect hose assembly (7) from the test bench to Tooling (J) .
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| Illustration 30 | g01038975 |
Supply Oil | |
- Connect hose assembly (8) from Tooling (K) to the No. 1 flow meter inlet.
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| Illustration 31 | g01065843 |
Transmission Oil Pump Outlet | |
- Connect hose assembly (9) from the outlet of the No. 1 flow meter to Tooling (L) .
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| Illustration 32 | g01040372 |
Main Relief Valve And Clutch Supply Rail Inlet | |
- Connect hose assembly (10) from Tooling (N) to the No. 2 flow meter inlet.
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| Illustration 33 | g01069610 |
Torque Converter Outlet | |
- Connect hose assembly (11) from the outlet of the No. 2 flow meter to Tooling (U) .
 | |
| Illustration 34 | g03876260 |
Transmission Lubrication Oil Inlet | |
- Connect lube line (12) from the test bench to Tooling (D). Maintain an oil pressure of 275 kPa (40 psi).
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| Illustration 35 | g01038981 |
Lubrication For The Spindle | |
- Connect two pressure gauges to pressure taps (13) and (14) .
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| Illustration 36 | g01069625 |
(13) Torque Converter Inlet Pressure Tap (14) Pump Pressure Tap | |
Note: If you are using individual pressure gauges to measure the pressures, refer to Table 3 for the correct pressure gauges.
- Connect pressure gauge (15) to Tooling (U) .
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| Illustration 37 | g03876268 |
Transmission Lubrication Pressure Tap | |
- Connect pressure gauge (16) to Tooling (M) .
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| Illustration 38 | g01069615 |
Torque Converter Outlet Pressure Tap | |
- Connect Tooling (P) to six clutch solenoids.
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| Illustration 39 | g01069629 |
"2-B" Cable connector (17) for No. 2 "FORWARD HIGH" solenoid "1-A" Cable connector (18) for No. 1 "FORWARD LOW" solenoid "3-C" Cable connector (19) for No. 3 "REVERSE" solenoid "4-D" Cable connector (20) for No. 4 "SECOND SPEED" solenoid "6-F" Cable connector (21) for No. 6 "FIRST SPEED" solenoid "5-E" Cable connector (22) for No. 5 "THIRD SPEED" solenoid | |
- Connect Tooling (P) to a suitable location.
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| Illustration 40 | g01065846 |
- Cover Tooling (C). Use a clean suitable cover.
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| Illustration 41 | g01038989 |
- Connect Tooling (P) to a power source. Refer to Tool Operating Manual, NEHS0644 or Tool Operating Manual, NEHS0996 for the correct operating instructions.
Note: Make sure that the transmission is secured to the test bench. Tighten all bolts to the proper torque.
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| Illustration 42 | g00877510 |
Tooling (P) | |
 | |
| Illustration 43 | g01457869 |
Tooling (P) | |
Test Procedure
TA3 Navigation
- Select "Wheel Loaders" or "Tool Carriers".
- Select "938H-24V", "938G-24V", or "IT38G-24V".
Harness Test (TA3 only)
- Make sure that the harness is properly connected.
- Use Tooling (P) to perform the harness test.
- Record the values in Table 7.
Note: Do not continue testing until Harness Test passes.
Solenoid Test (TA2 only)
- Make sure that the harness is properly connected.
- Use Tooling (P) to perform the solenoid test.
- Record the values in Table 7.
Note: Do not continue testing until Solenoid Test passes.
Start Checks
- The recommended oil is SAE 10W oil. Warm the oil to 50 °C (125 °F). If you are using Mobil DTE11 oil, warm the oil to 34 °C (95 °F). Maintain this temperature for the duration of the test.
Note: Refer to Testing and Adjusting, RENR6066-02, "938G Series 2 Wheel Loader and IT38G Series 2 Integrated Toolcarrier Power Train" for the correct adjusting procedures.
- With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 600 ± 25 rpm.
 | |
| Illustration 44 | g02720621 |
- Shift the transmission through all directions and through all speed ranges to eliminate air from the transmission controls.
- Confirm the correct clutch engagement with Table 4.
Show/hide table
Table 4 Clutch Engagement Check Gear Cl 1 Cl 2 Cl 3 Cl 4 Cl 5 Cl 6 N X F1 X X F2 X X F3 X X F4 X X R1 X X R2 X X R3 X X
- Stop the input rotation.
Main Relief Valve Check
- With the transmission in the NEUTRAL position, adjust the input rotation to 2200 ± 25 rpm.
- Measure the supply pressure. The supply pressure should be 2246 ± 70 kPa (326 ± 10 psi).
- Record the value in Table 8.
- Adjust the input rotation to 850 ± 25 rpm.
Relief Valve Check (Torque Converter Inlet)
- With the transmission in the NEUTRAL position, adjust the input rotation to 850 ± 25 rpm.
- Shift the transmission to FORWARD 1.
- Use Tooling (N) to block the flow at the torque converter outlet momentarily.
- The torque converter inlet pressure must be 1000 ± 140 kPa (148 ± 20 psi).
- Open Tooling (N) .
- Record the value in Table 9.
- Shift the transmission to the NEUTRAL position.
Low Idle Pressure Check
- With the transmission in the NEUTRAL position, adjust the input rotation to 850 ± 25 rpm.
- Record the input flow, the oil cooler flow, main pressure, torque converter inlet pressure, and lubrication pressure in Table 10.
- Compare the values with the values in Table 6.
- Shift the transmission through each FORWARD and REVERSE speed range. Repeat Steps 1 through 3.
Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.
- Shift the transmission to the NEUTRAL position.
- Stop the input rotation.
High Idle Pressure Check
- With the transmission in the NEUTRAL position, adjust the input rotation to 2200 ± 25 rpm.
- Record the input flow, the oil cooler flow, main pressure, torque converter inlet pressure, and lubrication pressure in Table 11.
- Adjust the input rotation to 850 ± 10 rpm.
- Compare the values with the values in Table 6.
- Shift the transmission through each FORWARD and REVERSE speed range. Repeat steps 1 through 4 for each position.
Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.
- Shift the transmission to the NEUTRAL position.
- Stop the input rotation.
Speed Sensor Test
- Connect Tooling (Q) to speed sensors .
Note: Transmission arrangements will have five speed sensors that must be tested. There is one input speed sensor, two intermediate speed sensors, and two output speed sensors. Identify each speed sensor.
 | |
| Illustration 45 | g01061608 |
Typical Example | |
- Adjust the input rotation to 850 ± 10 rpm.
- Shift the transmission to FORWARD 2.
- Use Tooling (Q) to measure the sensor signal voltage. Measure each speed sensor.
 | |
| Illustration 46 | g01070262 |
(23) Input Speed Sensor (24) Output Speed Sensor "No.1" (25) Output Speed Sensor "No.2" (26) Intermediate Speed Sensor "No.1" (27) Intermediate Speed Sensor "No.2" | |
- Record the values in Table 13.
- Verify the test points with the values in Table 12.
Contamination Control
- Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.
- Record the results in Table 14.
- Remove the transmission from the test bench if the test bench oil supply is within specifications.
Transmission Bench Test Data Sheet
| CATERPILLAR | Transmission Bench Test Data Sheet | Test Date:_______ |
| Model:_______ | ||
| Work Order:_______ | Serial No.:_______ | |
Specifications
| General Specifications | ||
| Description | High Idle | Low Idle |
| Input Speed | 2200 ± 25 rpm | 850 ± 25 rpm |
| Input Flow | 136 ± 8 L/min (36 ± 2 US gpm) |
53 ± 4 L/min (14 ± 1 US gpm) |
| Main Pressure | 2246 ± 70 kPa (326 ± 10 psi) |
2122 ± 70 kPa (308 ± 10 psi) |
| Torque Converter Inlet Pressure | 620 ± 70 kPa (90 ± 10 psi) |
- |
| Lubrication Pressure | 265 ± 50 kPa (38 ± 7 psi) |
41 ± 4 kPa (6 ± 2 psi) |
Solenoid Test
| Solenoid Test | Solenoid 1 | Solenoid 2 | Solenoid 3 | Solenoid 4 | Solenoid 5 | Solenoid 6 |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
Main Relief Valve Check
| Main Relief Valve Check | Input Speed (2200 ± 25 rpm) | _______kPa _______(psi) |
|||
Relief Valve Check (Torque Converter Inlet)
| Relief Valve Check (Torque Converter Inlet) | Input Speed (850 ± 25 rpm) | _______kPa _______(psi) |
|||
Low Idle Pressure Checks
| Low Idle Pressure Checks | Input Speed (850 ± 25 rpm) | |||||||
| Gear Range | N | 1F | 2F | 3F | 4F | 1R | 2R | 3R |
| Input Flow | ||||||||
| Oil Cooler Flow | ||||||||
| Main Pressure | ||||||||
| Torque Converter Inlet Pressure | ||||||||
| Lubrication Pressure | ||||||||
High Idle Pressure Checks
| High Idle Pressure Checks | Input Speed (2200 ± 25 rpm) | |||||||
| Gear Range | N | 1F | 2F | 3F | 4F | 1R | 2R | 3R |
| Input Flow | ||||||||
| Oil Cooler Flow | ||||||||
| Main Pressure | ||||||||
| Torque Converter Inlet Pressure | ||||||||
| Lubrication Pressure | ||||||||
Speed Sensor Test
| Sensor | Minimum Voltage | Maximum Voltage | ||
| Volts (Vpp) | Volts (VRMS) | Volts (Vpp) | Volts (VRMS) | |
| Input Speed | 4 Vpp | 1 VRMS | 8 Vpp | 3 VRMS |
| Intermediate Speed 1 | 2 Vpp | 1 VRMS | 4 Vpp | 1 VRMS |
| Intermediate Speed 2 | 2 Vpp | 1 VRMS | 4 Vpp | 1 VRMS |
| Output Speed 1 | 3 Vpp | 1 VRMS | 7 Vpp | 3 VRMS |
| Output Speed 2 | 3 Vpp | 1 VRMS | 7 Vpp | 3 VRMS |
| Speed Sensor Test | Output Speed (850 ± 10 rpm) Gear Range FORWARD 2 |
| Input Speed Sensor | __________________ Volts/Vrms |
| Output Speed Sensor 1 | __________________ Volts/Vrms |
| Output Speed Sensor 2 | __________________ Volts/Vrms |
| Intermediate Speed Sensor 1 | __________________ Volts/Vrms |
| Intermediate Speed Sensor 2 | __________________ Volts/Vrms |
Contamination Control
| Contamination Control | Sample the test bench oil supply. |
________/________Particle Count |
| ______________________________________ Technician |
______________________________________ Supervisor |