992G Wheel Loader AZX00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4013 - 22) - ...

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Product: WHEEL LOADER

Model: 992G WHEEL LOADER AZX
Configuration: 992G Wheel Loader AZX00001-UP (MACHINE) POWERED BY 3508B
Engine

Troubleshooting
992G Wheel Loader and 854G
Wheel Dozer Power Train
Media Number -SENR1347-05 Publication Date -01/10/2006 Date Updated -26/10/2006

i02775019

Torque Converter Troubleshooting

SMCS - 3101-035

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Illustration 1 g00109831

Schematic for the transmission hydraulic control

(1) Number 2 clutch solenoid

(2) Number 3 clutch solenoid

(3) Priority valve

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(4) Number 1 clutch solenoid

(5) Number 5 clutch solenoid

(6) Number 4 clutch solenoid

(7) Flow control orifice

(8) Lockup clutch solenoid valve (if equipped)

(9) Impeller clutch solenoid valve

(10) Slug

(11) Torque converter inlet ratio valve

(12) Slug

(13) Modulating relief valve

(14) Direction selection spool

(15) Torque converter

(16) Lockup clutch (if equipped)

(17) Impeller clutch

(18) Selector spool for first speed and for third speed

(19) Pressure differential valve

(20) Load piston

(21) Flow control orifice

(22) Selector spool for second speed

(23) Transmission oil filter

(24) Transmission oil filter

(25) Flow control orifice

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(26) Oil pump

(27) Torque converter outlet relief valve

(28) Oil cooler

(29) Magnetic Screen

(30) Lubrication passage for transmission

(31) Reservoir

(32) Reservoir

(A) Oil pump output pressure tap

(B) Pump pressure tap

(C) Pressure tap for lockup clutch (if equipped)

(D) Inlet pressure tap for the torque converter P3

(E) Speed clutch pressure tap P1

(F) Pressure tap for impeller clutch

(G) Direction clutch pressure tap P2

(H) Pump pressure tap

(I) Torque converter outlet pressure tap

(J) Transmission lubrication pressure tap

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

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machine is clear of personnel and obstructions before operating the

machine.

Personal injury can result from hydraulic oil pressure and hot oil.

Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure
is not released before any service is done on the hydraulic system.

Make sure all of the attachments have been lowered, oil is cool before
removing any components or lines. Remove the oil filler cap only when
the engine is stopped, and the filler cap is cool enough to touch with
your bare hand.

Escaping fluid under pressure, even a pinhole size leak, can penetrate
body tissue, causing 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.

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, "Caterpillar Dealer Service

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

Dispose of all fluids according to local regulations and mandates.

Operational Checks

Note: 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

z Torque converter pressure is high.

z Torque converter pressure is low.

z The torque converter overheats.

z The torque converter does not respond correctly for the left service brake pedal.

z The lockup clutch does not engage.

z The lockup clutch engages intermittently.

z The impeller clutch does not engage.

Troubleshooting

Note: In the following section, when components are referenced with a number, refer to the schematic
in 1.

Use the built-in electrical diagnostics that are performed with the Vital Information Management System
(VIMS) or Vital Information Display System (VIDS) and with the electronic control module in order to
determine the service codes for the power train electronic control module.

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Note: This machine is equipped with a power train electronic control. The power train electronic control
has built-in system diagnostics that detect faults in the electronic system of the power train.

ReferenceFor additional information on the operation of the power train electronic control module (ECM)
and troubleshooting the power train ECM, refer to the Service Manual module for Systems Operation,
Testing and Adjusting, "Power Train Electronic Control System" for the machine that is being serviced.

ReferenceFor additional information on troubleshooting the power train electronic control module (ECM),
refer to the Service Manual Module Systems Operation, Testing and Adjusting, SENR6059, "Vital
Information Management System (VIMS)" or Systems Operation, Testing and Adjusting, RENR6318,
"Vital Information Management System (VIMS)" for VIMS diagnostic procedures.

ReferenceFor additional information on troubleshooting the power train electronic control module (ECM),
refer to the Service Manual Module Service Manual, SENR1371, "Vital Information Display System
(VIDS)" for VIDS diagnostic procedures.

Probable Causes of Problems in the Torque Converter

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.

3. Torque converter inlet ratio valve (11) is stuck in the closed position.

Torque converter pressure is low

Probable causes

1. Torque converter inlet ratio valve (11) is stuck in the open position.

2. Adjustment of torque converter outlet relief valve (27) is not correct.

3. The valve spool in torque converter outlet relief valve (27) does not move.

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4. Pump flow or oil pressure is low. This may be caused by any of the following conditions:

a. The oil level is low.

b. There is a restriction in the oil flow circuit or a dirty oil strainer.

c. Oil pump failure.

d. Air leaks on the inlet side of the pump.

e. Leakage inside the transmission (worn seals around the clutch piston)

f. Modulating relief valve (13) is stuck open.

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 transfer gear case 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 ratio valve (11) is bypassing too much oil flow.

b. Pump flow or oil pressure is low. Refer to the Problem: Torque converter pressure is low.

The torque converter does not respond correctly to the left service brake pedal

Probable causes

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1. The torque converter is in the mode for reduced rimpull (if equipped). This changes the response
of the left service brake pedal.

2. The sensor for the left service brake pedal is calibrated incorrectly.

3. The left service brake pedal position sensor is faulty.

4. The impeller clutch solenoid or the impeller clutch solenoid valve is faulty.

5. There is a problem in the electrical circuit.

The lockup clutch does not engage

Probable causes

1. The on/off switch for the lockup clutch is not in the ON position.

2. The on/off switch for the lockup clutch is faulty.

3. The lockup clutch solenoid or the lockup clutch solenoid valve is faulty.

4. There is a problem in the electrical circuit.

The lockup clutch engages intermittently.

Probable causes

1. Erratic signals from the engine speed sensor or the torque converter speed sensor can cause the
lockup clutch in the torque converter to cycle on and off when the lockup clutch is enabled.

The impeller clutch does not engage

Probable causes

1. The impeller clutch solenoid or the impeller clutch solenoid valve is faulty.

2. There is a problem in the electrical circuit.

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Troubleshooting the Calibration of the Impeller Clutch

The calibration of the impeller clutch can generate error messages if a problem is encountered during
calibration. The following information is used to aid in troubleshooting the problem that was based on
the error message.

Table 1

Troubleshooting Information for the Calibration of the Impeller Clutch

Error Message Probable Causes Possible Corrective Actions

Use the throttle lock to set the engine speed

Engine speed is too above the following minimum values:
low. 2050 rpm ( 988G, 834G, 836G)
1650 rpm (992G,994D,854G)

Check for fault codes on the torque converter

output speed sensor.
Speed sensor problem
Check the sensor connector.
Adjust or replace the sensor, if necessary.
Torque converter output
Check valve function.
speed is low.
Check the connector.
Impeller clutch
Check ECM output.
pressure is too low.
Check the converter for excessive leakage in
the circuit for the impeller clutch.

Damaged impeller Check transmission screens.

clutch Inspect the impeller clutch.

Excessive drag in Check transmission screens.

transmission Inspect the impeller clutch.

Speed sensor problem Check for fault codes on the torque converter
output speed sensor.
Torque converter output Check the sensor connector.

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speed is high. Adjust or replace the sensor, if necessary.

Engine speed is too

Adjust the engine high idle speed.
high.

Check for fault codes on the torque converter

Speed sensor problem output speed sensor
Check the sensor connector.
Adjust or replace the sensor, if necessary.

Check valve function.

Check the solenoid connector.
Impeller clutch
Check ECM output.
pressure is too low.
Check the converter for excessive leakage in
the circuit for the impeller clutch.

The speed change of the Check for residual pressure in the circuit for the

torque converter is in the lockup clutch.

low range. Check the screens in the transmission for

material from the clutch.
Drag in the lockup
Inspect the lockup clutch for damaged discs or
clutch.
damaged plates.
If the lockup clutch has new discs, operate the
machine and engage the lockup clutch several
times. Repeat the calibration.

Check the screens in the transmission for

Excessive drag in the material from the clutch.
transmission Inspect the transmission for warped direction
clutches or damaged direction clutches.

Check valve function.

Holding pressure is too Check the solenoid connector.
high. Check the ECM output.
Impeller clutch Check the converter for excessive leakage in
pressure is out of the circuit of the impeller clutch.

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tolerance. Check for high torque converter inlet pressures

and outlet pressures.
Check the PTO system which is downstream of
the converter for restrictions.

Impeller clutch Check valve function.

Holding pressure is too
pressure is out of Check the solenoid connector.
low.
tolerance. Check ECM output.

Check valve function.

Check the solenoid connector.
Impeller clutch
Holding pressure Check ECM output.
pressure is not
inconsistent Check the converter for excessive leakage in
responding properly.
the circuit of the impeller clutch.
Check the transmission screens for debris.

Copyright 1993 - 2010 Caterpillar Inc.

Sun Feb 14 14:40:34 UTC+0630 2010
All Rights Reserved.
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