2000/03/20 Caterpillar

Wheel Loaders:

928F (PIN: 2XL1-UP; 8AK1-UP; 7YM1-UP)

928G (PIN: 7SR1-UP; 6XR1-UP)

938F (PIN: 1KM1-UP; 2RM1-UP; 8SM1-UP; 7SN1-UP)

938G (PIN: 4YS1-UP; 6WS1-UP; 8RS1-UP; 9HS1-UP)

Integrated Toolcarriers:

IT28F (PIN: 3CL1-UP; 1JL1-UP)

IT28G (PIN: 9AR1-UP; 8CR1-UP)

IT38F (PIN: 6FN1-UP; 5DR1-UP)

IT38G (PIN: 7BS1-UP; 1CW1-UP)

Service Manual module, SENR1217, "Power Train Disassembly and Assembly". The Service Manual module is found in the Service Manual, SENR1215. Service Manual module, SENR1215 covers 928G Wheel Loaders and IT28G Integrated Toolcarriers.Service Manual module, SENR5976-01, "Power Train Disassembly and Assembly". The Service Manual module is found in the Service Manual, SENR5970. Service Manual module, SENR5970 covers IT28F Integrated Toolcarriers.Service Manual module, SENR5995-01, "Power Train Disassembly and Assembly". The Service Manual module is found in the Service Manual, SENR5990. Service Manual module, SENR5990 covers 928F Wheel Loaders.Service Manual module, SENR6706-01, "Power Train Disassembly and Assembly". The Service Manual module is found in the Service Manual, SENR6700. Service Manual module, SENR6700 covers 938F Wheel Loaders and IT38F Integrated Toolcarriers.Service Manual module, SENR6787, "Power Train Disassembly and Assembly". The Service Manual module is found in the Service Manual, SENR6780, "Volume I". Service Manual module, SENR6780, "Volume I" covers 938G Wheel Loaders and IT38G Integrated Toolcarriers.

Make corrections, as follows. Service Manual module, SENR1217-01, "Power Train Disassembly and Assembly", "Disassemble & Assemble Transmission Control Valve" page 127. Service Manual module, SENR5976-01, "Power Train Disassembly and Assembly", "Disassemble & Assemble Transmission Control Valve" page 118. Service Manual module, SENR5995-01, "Power Train Disassembly and Assembly", "Disassemble & Assemble Transmission Control Valve" page 118. Service Manual module, SENR6706-01, "Power Train Disassembly and Assembly", "Disassemble & Assemble Transmission Control Valve" page 65.

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Illustration 1	g00685942

4. Remove bolts (4), differential valve (5) and dump valve (6) .

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Illustration 2	g00685935

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Illustration 3	g00685927

5. Remove plug (7) and remove the spool and the spring.

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Illustration 4	g00685947

6. Remove two dowels (8), seal (9) and O-ring seal (10) from the dump valve. Inspect the seals for damage.

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Illustration 5	g00685955

7. Remove rubber seal (11) from the back side of the dump valve. Inspect the seal for damage.

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Illustration 6	g00685966

8. Turn over dump valve (6). Remove plugs (12) and (15). Inspect the O-ring seals on the plugs for damage. Remove spring (14) and valve spool (13) from the valve body.

9. Remove plugs (16) and (23). Inspect the O-ring seals on the plugs for damage. Remove spring (22), piston (21) and valve spool (19) from the dump valve.

10. Remove plug (18). Inspect the O-ring seal on the plug for damage. Remove screen plug (20) from valve spool (19) .

11. Remove plug (17). Inspect the O-ring seal on the plug for damage.

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Illustration 7	g00685969

12. Remove socket head bolts (24) and (25) in order to separate manifold (27) from valve body (26) .

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Illustration 8	g00685974

13. Remove spacer plate (28) from manifold (27) .

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Illustration 9	g00685976

14. Remove seal (29) and inspect seal (29). Remove two dowels (30) from manifold (27) .

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Illustration 10	g00685978

15. Turn over manifold (27) and remove seal (31) .

16. Remove retainer ring (32) and then remove flow valve (33) .

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Illustration 11	g00686054

17. Turn over valve body (26). Remove seal (34), retainer (35), and spring (36) from the bottom of valve body (26) .

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Illustration 12	g00686067

18. Remove plugs (45) and remove valve spools (46) and springs (38). Remove slugs (47) and slug (39) .

19. Remove plugs (44) and remove springs (43) and slugs (41). Remove selector valve spool (42) and valve spools (40) from the valve body.

20. Remove solenoid valve assemblies (37) and (48) from the valve body.

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Illustration 13	g00686083

21. Remove the ball, the seat and spring assembly (53) from slug (39). Remove retainer ring (49), spacer (54) and spool (55) from valve spool (42). Remove screen plug (50) from spool (55). Remove slug (51) from spool (42). Remove slug (52) from spool (42) .

    Note: The following steps are used to assemble the transmission control valve.

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Illustration 14	g00686083

22. Install slug (51) and slug (52) into spool (42). Install screen plug (50) into spool (55). Install spool (55), spacer (54) and retainer ring (49) into spool (42) .

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Illustration 15	g00686067

23. Install solenoid valve assemblies (37) and (48) into valve body (26). Tighten the solenoid valve assemblies to a torque of 50 ± 5 N·m (37 ± 4 lb ft).

24. Install valve spools (40) and selector valve spool (42) into the valve body.

25. Install slugs (41), springs (43) and plugs (44) into the valve body.

26. Install valve spools (46), slugs (47), slug (39), springs (38) and plugs (45) into the valve body. Tighten the smaller plugs in plugs (44) and (45) to a torque of 37 ± 3 N·m (27 ± 2 lb ft). Tighten the larger plugs in plugs (44) and (45) to a torque of 75 ± 10 N·m (55 ± 7 lb ft).

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Illustration 16	g00686054

27. Turn over valve body (26) and install spring (36), retainer (35) and seal (34) .

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Illustration 17	g00685978

28. Install flow valve (33) and retainer ring (32) in manifold (27) .

29. Install seal (31) .

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Illustration 18	g00685976

30. Install dowels (30) and seal (29) in manifold (27) .

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Illustration 19	g00685974

31. Install spacer plate (28) onto manifold (27) .

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Illustration 20	g00685969

32. Install valve body (26) onto manifold (27) with socket head bolts (24) and (25) .

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Illustration 21	g00685966

33. Install the O-ring seal on plug (17). Install plug (17) in the dump valve. Tighten plug (17) to a torque of 14 ± 2 N·m (10 ± 1 lb ft).

34. Install plugs (12) and (16) in the dump valve. Install plug (18) in the valve body. Install screen plug (20) into valve spool (19). Install valve spool (19), piston (21) and spring (22) in the valve body. Install plug (23) .

35. Install valve spool (13) and spring (14) in the valve body. Install plug (15). Tighten plugs (16) and (23) to a torque of 37 ± 5 N·m (27 ± 4 lb ft). Tighten plugs (12) and (15) to a torque of 25 ± 4 N·m (18 ± 3 lb ft).

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Illustration 22	g00685955

36. Install rubber seal (11) on the bottom of the dump valve.

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Illustration 23	g00685947

37. Install two dowels (8), seal (9) and O-ring seal (10) onto the dump valve.

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Illustration 24	g00685935

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Illustration 25	g00685927

38. Install the spool, the spring and plug (7) .

    Note: Inspect the O-ring seal on plug (7). If the O-ring seal is worn or damaged, replace the O-ring seal.

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Illustration 26	g00685942

39. Install differential valve (5) and dump valve (6). Install bolts (4) .

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Illustration 27	g00686404

40. Remove tool (B) that is covering the porting for the control valve body. Install the transmission control valve body onto the transmission. Install hex head bolts (3) that hold the transmission control valve onto the transmission. Tighten hex head bolts (3) to a torque of 30 ± 4 N·m (22 ± 3 lb ft).

41. Connect wire connectors (2) to the transmission control valve body.

42. Remove the transmission assembly in position on tool (A) .

End By:

1. Connection of transmission to engine.

2. Install engine, transmission and transfer gears.

Make corrections, as follows. Service Manual module, SENR6787, "Power Train Disassembly and Assembly", "Transmission Hydraulic Control Valve - Disassemble" page 90.

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Illustration 28	g00685942

4. Remove bolts (4), differential valve (5) and dump valve (6) .

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Illustration 29	g00685935

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Illustration 30	g00685927

5. Remove plug (7) and remove the spool and the spring.

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Illustration 31	g00685947

6. Remove two dowels (8), seal (9) and O-ring seal (10) from the dump valve. Inspect the seals for damage.

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Illustration 32	g00685955

7. Remove rubber seal (11) from the back side of the dump valve. Inspect the seal for damage.

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Illustration 33	g00685966

8. Turn over dump valve (6). Remove plugs (12) and (15). Inspect the O-ring seals on the plugs for damage. Remove spring (14) and valve spool (13) from the valve body.

9. Remove plugs (16) and (23). Inspect the O-ring seals on the plugs for damage. Remove spring (22), piston (21) and valve spool (19) from the dump valve.

10. Remove plug (18). Inspect the O-ring seal on the plug for damage. Remove screen plug (20) from valve spool (19) .

11. Remove plug (17). Inspect the O-ring seal on the plug for damage.

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Illustration 34	g00685969

12. Remove socket head bolts (24) and (25) in order to separate manifold (27) from valve body (26) .

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Illustration 35	g00685974

13. Remove spacer plate (28) from manifold (27) .

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Illustration 36	g00685976

14. Remove seal (29) and inspect seal (29). Remove two dowels (30) from manifold (27) .

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Illustration 37	g00685978

15. Turn over manifold (27) and remove seal (31) .

16. Remove retainer ring (32) and then remove flow valve (33) .

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Illustration 38	g00686054

17. Turn over valve body (26). Remove seal (34), retainer (35), and spring (36) from the bottom of valve body (26) .

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Illustration 39	g00686067

18. Remove plugs (45) and remove valve spools (46) and springs (38). Remove slugs (47) and slug (39) .

19. Remove plugs (44) and remove springs (43) and slugs (41). Remove selector valve spool (42) and valve spools (40) from the valve body.

20. Remove solenoid valve assemblies (37) and (48) from the valve body.

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Illustration 40	g00686083

21. Remove the ball, the seat and spring assembly (53) from slug (39). Remove retainer ring (49), spacer (54) and spool (55) from valve spool (42). Remove screen plug (50) from spool (55). Remove slug (51) from spool (42). Remove slug (52) from spool (42) .

Make corrections, as follows. Service Manual module, SENR6787, "Power Train Disassembly and Assembly", "Transmission Hydraulic Control Valve - Assemble" page 94.

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Illustration 41	g00686083

1. Install slug (51) and slug (52) into spool (42). Install screen plug (50) into spool (55). Install spool (55), spacer (54) and retainer ring (49) into spool (42) .

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Illustration 42	g00686067

2. Install solenoid valve assemblies (37) and (48) into valve body (26). Tighten the solenoid valve assemblies to a torque of 50 ± 5 N·m (37 ± 4 lb ft).

3. Install valve spools (40) and selector valve spool (42) into the valve body.

4. Install slugs (41), springs (43) and plugs (44) into the valve body.

5. Install valve spools (46), slugs (47), slug (39), springs (38) and plugs (45) into the valve body. Tighten the smaller plugs in plugs (44) and (45) to a torque of 37 ± 3 N·m (27 ± 2 lb ft). Tighten the larger plugs in plugs (44) and (45) to a torque of 75 ± 10 N·m (55 ± 7 lb ft).

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Illustration 43	g00686054

6. Turn over valve body (26) and install spring (36), retainer (35) and seal (34) .

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Illustration 44	g00685978

7. Install flow valve (33) and retainer ring (32) in manifold (27) .

8. Install seal (31) .

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Illustration 45	g00685976

9. Install dowels (30) and seal (29) in manifold (27) .

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Illustration 46	g00685974

10. Install spacer plate (28) onto manifold (27) .

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Illustration 47	g00685969

11. Install valve body (26) onto manifold (27) with socket head bolts (24) and (25). The torque for the socket head bolts is 30 ± 4 N·m (22 ± 3 lb ft).

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Illustration 48	g00685966

12. Install the O-ring seal on plug (17). Install plug (17) in the dump valve. Tighten plug (18) to a torque of 14 ± 2 N·m (10 ± 1 lb ft).

13. Install plugs (12) and (16) in the dump valve. Install plug (18) in the valve body. Install screen plug (20) into valve spool (19). Install valve spool (19), piston (21) and spring (22) in the valve body. Install plug (23) .

14. Install valve spool (13) and spring (14) in the valve body. Install plug (15). Tighten plugs (16) and (23) to a torque of 37 ± 5 N·m (27 ± 4 lb ft). Tighten plugs (12) and (15) to a torque of 25 ± 4 N·m (18 ± 3 lb ft).

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Illustration 49	g00685955

15. Install rubber seal (11) on the bottom of the dump valve.

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Illustration 50	g00685947

16. Install two dowels (8), seal (9) and O-ring seal (10) onto the dump valve.

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Illustration 51	g00685935

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Illustration 52	g00685927

17. Install the spool, the spring and plug (7) .

    Note: Inspect the O-ring seal on plug (7). If the O-ring seal is worn or damaged, replace the O-ring seal.

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Illustration 53	g00685942

18. Install differential valve (5) and dump valve (6). Install bolts (4). Tighten bolts (4) to a torque of 30 ± 4 N·m (22 ± 3 lb ft).

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Illustration 54	g00686404

19. Install transmission control valve body (1) onto the transmission. Install hex head bolts (3) that hold the transmission control valve onto the transmission. Tighten hex head bolts (3) to a torque of 30 ± 4 N·m (22 ± 3 lb ft).

20. Connect wire connectors (2) to the transmission control valve body.

End By:

1. Install the cab.

   Reference: For information on installing the cab, refer to the Service Manual module Disassembly and Assembly, "Cab - Install" for the machine that is being serviced.