966H Wheel Loader TAL00001-UP (MACHINE) POWERED BY C11 Engine(SEBP542...

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Product: WHEEL LOADER

Model: 966H WHEEL LOADER TAL
Configuration: 966H Wheel Loader TAL00001-UP (MACHINE) POWERED BY C11 Engine

Testing and Adjusting

966H Wheel Loader and 972H
Wheel Loader Power Train
Media Number -RENR8846-09 Publication Date -01/12/2011 Date Updated -06/12/2011

i04542765

Transmission Pressures - Test and Adjust

SMCS - 3030-025-PX; 3030-081-PX; 7513-PK; 7554-PK

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, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.

Dispose of all fluids according to local regulations and mandates.

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1. Park the machine on a smooth, level surface.

2. Place the transmission direction and speed control lever (if equipped) in the NEUTRAL
position and in any speed position. Shift the transmission direction control switch (if equipped)
to the NEUTRAL position.

3. Lower the work tool to 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
(1)
198-4240 Digital Pressure Indicator 1
(1)
The 1U-5481 Pressure Gauge Group is also available.

Test Procedures
Remote Pressure Taps

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Illustration 1 g01099999

Location of the remote pressure taps

Illustration 2 g01165044

Remote pressure taps

(1) Transmission pressure tap for clutch 1

(2) Transmission pressure tap for clutch 2

(3) Transmission pressure tap for clutch 3

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(4) Transmission pressure tap for clutch 4

(5) Transmission pressure tap for clutch 5

(6) Transmission pressure tap for clutch 6

(7) Torque converter inlet pressure tap

(8) Torque converter outlet pressure tap

(9) Transmission lubrication pressure tap

(10) Transmission pump pressure tap (If Equipped)

The remote pressure taps for the torque converter and the transmission are located on the right side of
the machine under the cab.

Test for the Transmission Clutch Solenoid Modulating Valve

This test will determine whether the solenoid coil is energized and the solenoid plunger is shifting in
order to permit the flow of oil through the transmission clutch solenoid modulating valve.

Hearing the click of a solenoid or using a screwdriver to check that the solenoid coil is energized does
not ensure that the solenoid plunger has shifted. The following test will determine if the solenoid
plunger is shifting.

Table 2
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

1. Install the correct hose assembly from the 198-4240 Digital Pressure Indicator onto pressure tap
(1) through pressure tap (6) .

2. Engage the parking brake. Shift the transmission direction and speed control lever (if equipped)
to the NEUTRAL position. Shift the transmission direction control switch (if equipped) to the
NEUTRAL position. Start the engine and operate the engine at low idle.

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3. Use the transmission neutralizer override switch in order to disengage the transmission
neutralizer.

4. Depress the right service brake pedal and hold the right service brake pedal. Make sure that the
machine is in first speed. Release the parking brake. Watch the pressure gauges. Move the
transmission direction and speed control lever (if equipped) from the NEUTRAL position to the
FORWARD position. Shift the transmission direction control switch (if equipped) from the
NEUTRAL position to the FORWARD position.

The pressure on the pressure gauge for the Number 2 clutch should rise. The pressure on the
pressure gauge for the Number 6 clutch should rise. With the transmission in the FORWARD
position, shift through the remaining forward speeds and return to the FIRST SPEED position.
Use the transmission direction and speed control lever or the transmission upshift switch to
change speeds. The same pressure rise should be observed in each respective speed. This
checks the operation of all the speed clutches.

5. Perform Step 4 for all reverse speeds. The same pressure rise should be noted in all reverse
speeds.

If a pressure rise is noted, the solenoid and the related electrical circuit are functioning.

If a pressure rise is not noted, use a screwdriver to check that the solenoid coil is energized. If the
screwdriver is attracted to the solenoid coil, this indicates that the solenoid coil is energized. The
problem is in the solenoid cartridge. The problem could be a bent solenoid stem, a screen that is dirty
or plugged, or a spring that is weak or broken.

If the screwdriver does not indicate that the solenoid coil is energized, the problem is in the electrical
circuit.

ReferenceFor additional information about calibrating the transmission clutch solenoid modulating
valves, refer to the Service Manual module Testing and Adjusting, "Calibration and Programming"
for the machine that is being serviced.

ReferenceFor additional information about calibrating the transmission clutch solenoid modulating
valves, refer to the Service Manual module Testing and Adjusting, "Fill Time for the Transmission
Clutch - Calibrate" for the machine that is being serviced.

ReferenceFor additional information about electrical system troubleshooting, refer to the Service
Manual module Testing and Adjusting, "Troubleshooting Diagnostic Codes" for the machine that is
being serviced.

Test for the Transmission Clutch Pressure

Use the following procedure to check the pressure of the direction clutch oil and the speed clutch oil.

1. Install the correct hose assembly from the 198-4240 Digital Pressure Indicator on pressure tap
(1) through pressure tap (6) .

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2. Engage the parking brake. Shift the transmission direction and speed control lever (if equipped)
to the NEUTRAL position. Shift the transmission direction control switch (if equipped) to the
NEUTRAL position. Start the engine and operate the engine at low idle.

3. Use the transmission neutralizer override switch in order to disengage the transmission
neutralizer.

4. Depress the right service brake pedal and hold the right service brake pedal. Make sure that the
machine is in first speed. Release the parking brake. Watch the pressure gauges. Shift the
transmission direction and speed control lever (if equipped) from the NEUTRAL position to the
FORWARD position. Shift the transmission direction control switch (if equipped) from the
NEUTRAL position to the FORWARD position. Increase the engine speed to high idle. Make
sure that the transmission oil is at normal operating temperature. The pressure on the pressure
gauge for the Number 2 clutch should rise. The pressure on the pressure gauge for the Number
6 clutch should rise. The pressure readings must be within the values in Table 4.

With the transmission in the FORWARD position, shift through the remaining forward speeds
and return to the FIRST SPEED position. Use the transmission direction and speed control
lever (if equipped) or the transmission upshift switch (if equipped) to change speeds. The
pressure reading for each energized clutch must be within the values in Table 4. This checks the
pressure of all the speed clutches.

5. Perform Step 4 for all reverse speeds. The same pressure levels should be noted in all reverse
speeds.

Adjustments for the Transmission Clutch Pressure

If the pressure reading for each energized clutch is not within the values in Table 4, the transmission
clutch solenoid modulating valve may need to be replaced or the pump pressure may need adjustment.

ReferenceFor additional information about calibrating the transmission clutch solenoid modulating
valves, refer to the Service Manual module Testing and Adjusting, "Fill Time for the Transmission
Clutch - Calibrate" for the machine that is being serviced.

ReferenceFor additional information about electrical system troubleshooting, refer to the Service
Manual module Testing and Adjusting, "Troubleshooting Diagnostic Codes" for the machine that is
being serviced.

Test for the Lubrication Oil Pressure

Use the following procedure to check the pressure of the transmission lubrication oil.

The pressure tap for the transmission lubrication oil is located on the right side of the machine under
the cab behind an access panel. Refer to Illustration 1 and Illustration 2.

1. Install the correct hose assembly from the 198-4240 Digital Pressure Indicator on pressure tap
(9) .

2. Start the engine and operate the engine at high idle. Observe the pressure gauge. With the oil at
normal operating temperature, the lubrication oil pressure must be within the values in Table 4.

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Test of the Torque Converter Outlet Pressure

Use the following procedure to check oil pressure at the torque converter outlet.

Note: Some machines are equipped with a torque converter outlet relief valve. This test procedure is
valid for all machine configurations.

1. Install the correct hose assembly from the 198-4240 Digital Pressure Indicator on pressure tap
(8) .

2. Start the engine and run the machine at the torque converter stall. With the oil at normal
operating temperature, the torque converter outlet pressure must be within the values in Table 4.

Adjustment For The Torque Converter Outlet Pressure

Illustration 3 g01023672

(1) Cover

(2) Torque converter outlet relief valve

(H) Pressure tap

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Illustration 4 g01023671

Torque Converter Outlet Relief Valve

(1) Cover

(3) Relief valve spool

(4) Spacers

(5) Spring

Table 3
Spacers
Pressure Change for the Valve (1)
Description Thickness Pressure Change Location of Spacers

4M-1751 Spacer 0.41 mm (.016 inch)

19 kPa (2.7 psi)
Outlet relief valve
5S-7001 Spacer
0.91 mm (.036 inch) 40 kPa (6 psi)

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(1)
Result of the addition of one spacer or the removal of one spacer to the valve.

1. Remove cover (1) from torque converter outlet relief valve (2) .

Note: Remove the cover slowly in order to keep the spring in the housing.

2. Remove spring (5) and spacers (4) from spool (3) within the valve.

3. Add or remove spacers (4) from the pack of springs in order to attain the desired pressure.

ReferenceRefer to Table 3 for information about the spacers.

4. Install spacers (4) and spring (5) .

5. Install cover (1) and tighten the bolts.

Test for the Transmission Oil Pump Pressure

Use the following procedure to check transmission oil pump pressure.

1. Install the correct hose assembly from the 198-4240 Digital Pressure Indicator on pressure tap
(10) (If Equipped).

Note: If the machine is not equipped with the remote pressure tap use the transmission pump
discharge pressure tap on the transmission filter in the hydraulic service center.

2. Start the engine and operate the engine at high idle. Observe the pressure gauges. With the oil at
normal operating temperature, the transmission oil pump pressure must be within the values in
Table 4.

Adjustment for the Transmission Oil Pump Pressure

The transmission hydraulic control relief valve is located on the left side of the machine on the torque
converter housing.

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Illustration 5 g00500335

Transmission Hydraulic Control Relief Valve

(L) Cover

Illustration 6 g00500338

Transmission Hydraulic Control Relief Valve

(M) Adjustment screw

If the transmission oil pump pressure at pressure tap (10) is not within the values in Table 4, adjust the
spring of the transmission hydraulic control relief valve. Use the following procedure.

1. Remove cover (L) .

2. Turn adjustment screw (M) in the proper direction.

Turning the adjustment screw clockwise increases pump pressure. Turning the adjustment
screw counterclockwise decreases pump pressure. One full turn of the adjustment screw
changes pump pressure 160 kPa (23 psi).

3. Install cover (L) .

4. Check the transmission oil pump pressure again. Make sure that the transmission oil pump
pressure is within the value in Table 4.

Test for the Torque Converter Inlet Pressure

1. Install the correct hose assembly from the 198-4240 Digital Pressure Indicator on pressure tap
(7) .

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2. Start the engine and run the machine at the torque converter stall. Observe the pressure gauge.
With the oil at normal operating temperature, the torque converter inlet pressure must be within
the values in Table 4.

Transmission and Torque Converter Pressures

Table 4
Transmission Pressures for the 966H and 972H Wheel Loaders (1)
Pressure Tap Specification

(1) Number 1 clutch pressure

2758 ± 140 kPa (400 ± 20 psi)

(2) Number 2 clutch pressure

2758 ± 140 kPa (400 ± 20 psi)

(3) Number 3 clutch pressure

2758 ± 140 kPa (400 ± 20 psi)

(4) Number 4 clutch pressure

2758 ± 140 kPa (400 ± 20 psi)

(5) Number 5 clutch pressure

2310 ± 140 kPa (335 ± 20 psi)

(6) Number 6 clutch pressure

2758 ± 140 kPa (400 ± 20 psi)

(7) Torque converter inlet pressure

550 kPa (80 psi)

(8) Torque converter outlet pressure

415 ± 140 kPa (60 ± 20 psi)

(9) Transmission lubrication pressure

105 kPa (15 psi) (minimum)

(10) Transmission oil pump pressure

2758 ± 70 kPa (400 ± 10 psi)
(1)
Oil pressure at high idle.

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