938G PT Taa PDF

938G Wheel Loader 4YS00001-UP (MACHINE) POWERED BY 3126 Engine(SEB...
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Produit: WHEEL LOADER
Modèle : 938G WHEEL LOADER 4YS
Configuration: 938G Wheel Loader 4YS00001-UP (MACHINE) POWERED BY 3126 Engine

Essai et réglage
938G Wheel Loader and IT38G Integrated Toolcarrier Power Train
Numéro d'imprimé -SENR6785-03 Date de publication -01/11/2000 Date de mise à jour -09/10/2001

i00872653
Power Train Troubleshooting

SMCS - 3000-035

Illustration 1 g00281968
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938G Wheel Loader 4YS00001-UP (MACHINE) POWERED BY 3126 Engine(SEB... Page 2 sur 15
Schematic for the Transmission Hydraulic System
(1) Flow control valve
(2) Transmission hydraulic control valve
(3) Selector spool and slug (Forward High)
(4) No. 1 solenoid (Forward High)
(5) Selector spool and slug (Forward Low)
(6) No. 2 solenoid (Reverse)
(7) Selector spool and slug (Reverse)
(8) No. 3 solenoid (Forward Low)
(9) Check valve
(10) Screen orifice
(11) Modulating relief valve
(12) Slug
(13) Differential valve
(14) Spring
(15) Valve spool
(16) Differential relief valve
(17) Spring
(18) Poppet
(19) Load piston springs
(20) Converter backflow check valve
(21) Load piston
(22) Transmission oil filter
(23) Selector spool and slug (First Speed)
(24) Transmission dump valve
(25) Transmission oil pump
(26) No. 4 solenoid (First Speed)
(27) Selector spool and slug (Second Speed)
(28) Selector spool and slug (Third Speed)
(29) No. 6 solenoid (Third Speed)
(30) No. 5 solenoid (Second Speed)
(31) Torque converter inlet relief valve
(32) Suction screen and magnet
(33) Torque converter
(34) Oil cooler
(35) Transmission lubrication
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.
To prevent injury or death, make sure that the area around the
machine is clear of personnel and obstructions before operating the
machine.
NOTICE
Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting and repair
of the machine. 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 in Caterpillar machines.
Dispose of all fluids according to local regulations and mandates.
Operational Checks
Operate the machine in each direction and in all speeds. Note the noises that are not normal and find
the sources of the noises. If the machine is not operating correctly, refer to the "Troubleshooting
Problem List" below.
Troubleshooting Problem List

• The transmission does not operate in any speed or the transmission slips in all speeds.
• The transmission overheats.
• Pump noise is not normal.
• Noise in the transmission is not normal.
• The transmission operates in FORWARD only.
• The transmission operates in REVERSE and in FOURTH SPEED FORWARD only.
• The transmission operates in REVERSE and in FIRST through THIRD SPEED FORWARD
only.
• The transmission does not operate in FIRST SPEED FORWARD or in FIRST SPEED
REVERSE.
• The transmission does not operate in SECOND SPEED FORWARD or in SECOND SPEED
REVERSE.
• The transmission does not operate in THIRD SPEED FORWARD, in REVERSE, or in
FOURTH SPEED FORWARD.
• The transmission does not operate in FOURTH SPEED FORWARD. However, the
transmission operates in THIRD SPEED REVERSE.
• Pressure is low at speed clutch pressure tap P1 and at direction clutch pressure tap P2 when the
machine is operated in all directions and in all speeds.
• Pressure is low at direction clutch pressure tap P2 when the machine is operated in REVERSE
speeds.
• Pressure is low at direction clutch pressure tap P2 when the machine is operated in FORWARD
speeds.
• Pressure is high at speed clutch pressure tap P1 and at direction clutch pressure tap P2 when the
machine is operated in all directions and in all speeds.
• The pressure differential between P1 and P2 is not correct.
• Clutch engagement is sudden. (This causes jerky shifting.)
• Clutch engagement is slow. (This causes slow shifting in all gears.)
• Clutch engagement is slow in all FORWARD gears, in all REVERSE gears, or in any one gear
speed (FORWARD and REVERSE).
• There is a loss of power when the transmission is shifted from THIRD SPEED to FIRST
SPEED.
• The transmission neutralizer is actuated and the transmission remains engaged.
• Even though the transmission engages, the machine does not move and the engine lugs.
• The engine is running and the parking brake is engaged. However, the action alarm does not
sound when the transmission is put into the FORWARD direction or into the REVERSE
direction.
• The backup alarm does not sound when the transmission is put in REVERSE.
• Stall speed is low.
• Stall speed is high when the machine is operated in both directions.
• Stall speed is high when the machine is operated in one direction or in one speed.
• The lubrication pressure is low.
• The lubrication pressure is high.
• Torque converter pressure is low.
• Torque converter pressure is high.
• The torque converter overheats.
• There is constant noise in the differential.
• Noise occurs in the differential at different intervals.
• Noise only occurs during turns.
• Lubricant is leaking.
• The drive wheels do not turn, but the universal joint turns.
Troubleshooting
Note: When components are called out in the following section, refer to Illustration 1.
Reference: This machine has a transmission electronic control. Refer to Service Manual, SENR1218,
"Transmission Electronic Control System" for information about troubleshooting the transmission
electronic control.
Probable Causes of Power Train Problems

Problem: The transmission does not operate in any speed or the transmission slips in all speeds.
Probable causes:
1. The transmission fuse is missing or broken.
2. There is a problem in the electrical circuit for the transmission.
3. The system voltage is low.
4. The transmission direction and speed control is faulty.
5. Oil pressure is low. This may be caused by any of the following conditions:
a. Oil level is low.
b. An oil strainer is dirty or there is a restriction in the oil flow circuit.
c. An oil pump failed.
d. Air is leaking on the inlet side of the pump.
e. There is leakage inside the transmission (worn seals around the clutch shaft or around the
clutch piston).
f. Modulating relief valve (11) is stuck open.
6. There is a torque converter failure.
7. There is a mechanical failure in the transmission.
8. Clutch discs and clutch plates are excessively worn.
9. The transmission neutralizer switch is not operating.
10. Check valve (9) is stuck open.
Problem: The transmission overheats.
Probable causes:
1. Coolant level in the radiator is low.
2. The machine is being used for the wrong application. There is too much torque converter slip,
which is caused by too much load.
3. Incorrect transmission gear is being used for the load that is on the machine. Shift to a lower
gear.
4. The temperature gauge is faulty.
5. The oil level is incorrectly high or low.
6. The oil cooler or oil lines are restricted.
7. The clutch slips too much. This may be caused by any of the following conditions:
a. Oil pressure is low.
Note: For the probable causes of low oil pressure, refer to Cause 5 in the problem "The
transmission does not operate in any speed or the transmission slips in all speeds".
b. A clutch is damaged.
8. Oil flow is low. This may be caused by pump wear or by leakage in the hydraulic system.
9. There is air in the oil. This may be caused by air leaks on the intake side of the pump.
10. Torque converter inlet relief valve (31) is stuck open. This causes low oil flow through the
torque converter.
11. The clutch or clutches are not fully released. (This is called clutch drag.) This may be caused
by any of the following conditions:
a. Plates and/or discs are warped.
b. A return spring is broken or weak.
Problem: Pump noise is not normal.
Probable causes:
1. A loud noise at short intervals indicates that foreign material is in the transmission hydraulic
system.
2. A constant loud noise indicates pump failure.
3. There is air at the inlet side of the pump.
Problem: Noise in the transmission is not normal.
Probable causes:
1. Transmission components are worn or damaged.
a. Gears are damaged.
b. Teeth on the clutch plates and/or on the clutch discs are worn.
c. Clutch plates are slipping and the clutch discs are making noise.
d. Other transmission components are worn or damaged.
Problem: The transmission operates in FORWARD only.
Probable causes:
1. Number 2 REVERSE clutch solenoid (6) is inoperative.
2. There is a problem in the electrical circuit.
3. The REVERSE clutch is not engaged or the REVERSE clutch slips. This may be caused by
any of the following conditions:
a. Oil pressure is low due to leaking piston seals or due to leaking shaft seals.
b. The clutch discs and clutch plates have too much wear.
c. Clutch components are broken.
4. Selector spool (7) is stuck.
Problem: The transmission operates in REVERSE and in FOURTH SPEED FORWARD only.
Probable causes:
1. Number 3 FORWARD LOW clutch solenoid (8) is inoperative.
3. The FORWARD LOW clutch is not engaged or the FORWARD LOW clutch slips. This may
be caused by any of the following conditions:
Problem: The transmission operates in REVERSE and in FIRST through THIRD SPEED
FORWARD only.
Probable causes:
1. Number 1 FORWARD HIGH clutch solenoid (4) is inoperative.
3. The FORWARD HIGH clutch is not engaged or the FORWARD HIGH clutch slips. This may
a. Oil pressure is low due to leaking piston seals.
Problem: The transmission does not operate in FIRST SPEED FORWARD or in REVERSE.
Probable causes:
1. Number 4 FIRST SPEED clutch solenoid (26) is inoperative.
3. The FIRST SPEED clutch is not engaged or the FIRST SPEED clutch slips. This may be
caused by any of the following conditions:
Problem: The transmission does not operate in SECOND SPEED FORWARD or in

REVERSE.
1. Number 5 SECOND SPEED clutch solenoid (30) is inoperative.
3. The SECOND SPEED clutch is not engaged or the SECOND SPEED clutch slips. This may be
a. Oil pressure is low due to leaking piston seals.
Problem: The transmission does not operate in THIRD SPEED FORWARD, in REVERSE, or
in FOURTH SPEED FORWARD.
Probable causes:
1. Number 6 THIRD SPEED clutch solenoid (29) is inoperative.
3. The THIRD SPEED clutch is not engaged or the THIRD SPEED clutch slips. This may be
Problem: The transmission does not operate in FOURTH SPEED FORWARD. However, the
transmission operates in THIRD SPEED FORWARD.
Probable causes:
1. Number 1 FORWARD HIGH clutch solenoid (4) is inoperative.
3. The FORWARD HIGH clutch is not engaged or the FORWARD HIGH clutch slips. This may
Problem: Pressure is low at speed clutch pressure tap P1 and at direction clutch pressure tap
P2 when the machine is operated in all directions and in all speeds.
Probable causes:
1. Modulating relief valve (11) is stuck.
2. Oil pressure is low.
3. Springs of load piston (19) are weak or damaged. Springs or spacers are missing.
4. Transmission dump valve (24) is stuck open.
5. Flow control valve (1) is stuck open.
6. Check valve (9) is stuck open.
Problem: Pressure is low at direction clutch pressure tap P2 when the machine is operated in
REVERSE speeds.
Probable causes:
There is too much leakage in the piston seals or in the shaft seals of the REVERSE clutch.
Problem: Pressure is low at direction clutch pressure tap P2 when the machine is operated in
FORWARD speeds.
Probable causes:
938G Wheel Loader 4YS00001-UP (MACHINE) POWERED BY 3126 Engine(S... Page 10 sur 15
There is too much leakage in the piston seals or in the shaft seals of the FORWARD clutch.
Problem: Pressure is high at speed clutch pressure tap P1 and at direction clutch pressure tap
P2 when the machine is operated in all directions and in all speeds.
Probable causes:
1. Modulating relief valve (11) is sticking.
2. Load piston (21) is stuck.
3. The wrong load piston springs (19) are being used.
4. Slug (12) is worn. The bore for the modulating relief valve (11) is worn.
Problem: The pressure differential between P1 and P2 is not correct.
Probable causes:
1. Pressure differential valve (13) is not operating correctly. This may be caused by any of the
following conditions:
a. Spring (14) is weak or damaged.
b. The wrong spring (14) was installed.
c. Valve spool (15) is faulty.
2. Differential relief valve (16) is not operating correctly. This may be caused by any of the
c. Poppet (18) is faulty.
3. Flow control valve (1) is stuck in the closed position.
Problem: Clutch engagement is sudden. (This causes jerky shifting.)
Probable causes:
1. Pressure differential valve (13) is not operating correctly. This may be caused by any of the
c. Valve spool (15) is faulty.
2. Differential relief valve (16) is not operating correctly. This may be caused by any of the
c. Poppet (18) is faulty.
3. Load piston (21) is stuck.
4. The wrong load piston springs (19) are being used or the load piston springs are damaged.
5. Transmission dump valve (24) is stuck in the closed position.
6. Converter backflow check valve (20) is not seating or the converter backflow check valve is
missing.
Problem: Clutch engagement is slow. (This causes slow shifting in all gears.)
Probable causes:
1. Check valve (9) is not closing or check valve (9) is open to the drain. Screen orifice (10) for the
load piston is dirty or plugged.
3. Load piston springs (19) are weak or damaged.
4. Modulating relief valve (11) is stuck.
Problem: Clutch engagement is slow in all FORWARD gears, in all REVERSE gears, or in any
one gear speed (FORWARD and REVERSE).
Probable causes:
Clutch pressure is low because of leaking seals on the piston or on the shaft for the affected gear.
Problem: There is a loss of power when the transmission is shifted from THIRD SPEED to
FIRST SPEED.
Probable causes:
The return spring for selector spool (28) is broken or missing. The two clutches are engaged
incorrectly.
Problem: The transmission neutralizer is actuated and the transmission remains engaged.
Probable causes:
1. The transmission neutralizer switch must be adjusted correctly.
2. The transmission neutralizer switch has failed.
Problem: Even though the transmission engages, the machine does not move and the engine
lugs.
Probable causes:
1. The service brakes are locked up.
2. The parking brake is not released. Also, the parking brake may be locked up.
3. There is a mechanical failure in a differential (front differential or rear differential).
4. There is a mechanical failure in a final drive.
5. Gears in the transmission do not turn because there is a mechanical failure in the transmission.
Problem: The engine is running and the parking brake is engaged. However, the action alarm
does not sound when the transmission is put into the FORWARD direction or into the
REVERSE direction.
Probable causes:
1. The action alarm has failed.
Problem: The backup alarm does not sound when the transmission is put in REVERSE.
Probable causes:
1. The backup alarm fuse has failed.
2. The backup alarm has failed.
Problem: Stall speed is low.
Probable causes:
1. Engine performance is not correct.
2. The oil is cold.
Problem: Stall speed is high when the machine is operated in both directions.
Probable causes:
1. Oil level is low.
2. There is air in the oil.
3. Direction clutches are slipping.
4. There is a failure in the torque converter.
Problem: Stall speed is high when the machine is operated in one direction or in one speed.
Probable causes:
1. There is a leak in the clutch circuit.
2. There is a failure in the direction clutch or in the speed clutch that has high stall speed.
Problem: The lubrication pressure is low.
Probable causes:
1. The torque converter inlet relief valve (31) is bypassing too much oil flow.
Problem: The lubrication pressure is high.
Probable causes:
The lubrication holes in the clutch shafts are blocked.
Problem: The torque converter pressure is high.
Probable causes:
1. There is a restriction inside the torque converter.
2. There is a restriction in an oil passage or in the oil cooler.
Problem: The torque converter pressure is low.
Probable causes:
1. The torque converter inlet relief valve (31) is bypassing too much oil flow.
Problem: The torque converter overheats.
Probable causes:
1. The machine is being used for the wrong application. There is too much torque converter slip,
which is caused by too much load.
2. Incorrect transmission gear is being used for the load that is on the machine. Shift to a lower
gear.
3. The oil level in the transmission is incorrectly high or low.
4. The coolant level in the engine radiator is low.
5. The oil cooler or oil lines are restricted.
6. Oil flow through the torque converter is too low. This may be caused by any of the following
conditions:
a. The torque converter inlet relief valve (31) is bypassing too much oil flow.
b. Pump flow or oil pressure is low.
Note: For the probable causes, refer to the problem "The torque converter pressure is

low".
Problem: There is constant noise in the differential.
Probable causes:
1. The level of lubricant is incorrectly high or low.
2. The wrong type of lubricant is being used.
3. Wheel bearings are damaged or improperly adjusted.
4. The ring gear and the pinion do not have correct tooth contact.
5. The ring gear and the pinion are damaged or worn.
6. There is too much pinion to gear backlash or too little pinion to gear backlash.
7. Pinion bearings are loose or worn.
8. Side bearings are loose or worn.
Problem: Noise occurs at different intervals.
Probable causes:
1. Ring gear does not run evenly because the bolts on the ring gear are not tight or the ring gear is
warped.
2. Differential bearings are loose or broken.
Problem: Noise only occurs during turns.
Probable causes:
1. Differential pinion gears are too tight on the retainer pins or on the pinion shaft.
2. Side gears are too tight in the differential case.
3. Differential pinion gears or side gears are faulty.
4. Thrust washers are damaged or worn.
5. There is too much backlash between the side gears and the pinion gears.
Problem: Lubricant is leaking.
Probable causes:
1. Loss of lubricant through the axle shafts can be caused by any of the following conditions:
a. Lubricant is above the proper level.
b. The wrong type of lubricant is being used.
c. There is a restriction in the axle housing breather.
d. An oil seal on the axle shaft is worn or installed incorrectly.
2. Loss of lubricant at the pinion shaft can be caused by the following conditions:
a. Lubricant is above the proper level.
b. The wrong type of lubricant is being used.
c. There is a restriction in the axle housing breather.
d. An oil seal on the pinion shaft is worn or installed incorrectly.
e. A universal joint flange is loose on the pinion shaft.
Problem: The drive wheels do not turn but the universal joint turns.
Probable causes:
1. An axle shaft is broken.
2. Ring gear teeth are damaged.
3. The side gear or the differential pinion is broken.
4. The differential pinion shaft or the retainer pin is broken.
Copyright 1993 - 2017 Caterpillar Inc. Tue Jun 13 19:22:44 UTC 2017
Tous droits réservés.
Réseau privé pour utilisateurs autorisés de SIS.

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938G Wheel Loader 4YS00001-UP (MACHINE) POWERED BY 3126 Engine(SEB...

Power Train Troubleshooting

Personal injury or death can result from sudden machine movement.

Sudden movement of the machine can cause injury to persons on or

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Dispose of all fluids according to local regulations and mandates.

Troubleshooting Problem List

Probable Causes of Power Train Problems

Problem: The transmission overheats.

Problem: Pump noise is not normal.

Problem: Noise in the transmission is not normal.

Problem: The transmission operates in FORWARD only.

Problem: The transmission does not operate in SECOND SPEED FORWARD or in

Problem: The pressure differential between P1 and P2 is not correct.

Problem: Clutch engagement is sudden. (This causes jerky shifting.)

Problem: Stall speed is low.

Problem: The lubrication pressure is low.

Problem: The lubrication pressure is high.

Problem: The torque converter pressure is high.

Problem: The torque converter pressure is low.

Problem: The torque converter overheats.

Note: For the probable causes, refer to the problem "The torque converter pressure is

Problem: There is constant noise in the differential.

Problem: Noise occurs at different intervals.

Problem: Noise only occurs during turns.

Problem: Lubricant is leaking.

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