SERV2739

iTIM for RENR6066

March 2003

Integrated Technical
Instruction Module

938G Series II Wheel Loader and

IT38G Series II Integrated Toolcarrier
Power Train
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Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Objectives/Student Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Lesson Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Preparation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Visual/Text Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Laboratory Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Case Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Posttest: Power Train Hydraulic Components and Function . . . . . . . . . . . . . . . . . . . .26

Posttest: Power Train Electronic Control System Components and Function . . . . . . .27

Instructor Answer Key and Lab Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

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Introduction
This Integrated Technical Instruction Module is a portion of the course on the 938G Series II Wheel
Loader and IT38G Series II Integrated Toolcarrier. The power train is covered in this iTIM.

Prerequisites
All students should have some overall experience with Caterpillar equipment and have a basic working
knowledge of servicing electrical and electronic systems. Basic computer skills are also required.

Prerequisite tests should be administered at least a few weeks before the participant takes the course.

Participants should pass the following pretests with a score of 90% or better:

Machine Electrical Pretest SEBV0558

Basic Hydraulic Pretest SEBV0557

Graphic Fluid Power Symbols (Pretest) SEBV0556

If a participant does not accomplish 90% or better, identify the area of deficiency and then refer to the
pretest for the recommended course or courses for the student to review. After ample review time, the
student should retake the test.

NOTE:
Understanding the operation and function of the power train on these wheel loaders is critical for
troubleshooting. It is also important to be able properly test and adjust the system.

Objectives/Student Evaluation
The objectives identify the skills that are taught in this iTIM. Prior to conducting the course, the instructor
should use the objectives to assess what student skills need improvement and if a student needs to
attend the course. At course completion, the instructor should use the objectives to document student
progress. The instructor should sign the students' completed objectives and forward it to students'
supervisor.

Prior to taking the course, students should review the objectives and assess their current skill level.
During the course students should use the objectives as a learning guide. At course completion,
students should use the objectives to compare their pre-class and post-class skill level.
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Objectives/Student Evaluation
Student Name: ________________________ Instructor(s):_______________________

Course Name: _________________________ Course Number: ___________________

Pretest Score: ________ Posttest Score: ____________

Instructor
Did student accomplish the following objectives? Additional remarks
Yes No

1. Given Lab A worksheet, the "938G Series II Wheel Loader

and IT38G Series II Integrated Toolcarrier Power Train
Systems Operation Testing and Adjusting" manual, and a
938G Series II Wheel Loader or IT38G Series II Integrated
Toolcarrier, locate power train components.
2. Given Lab B worksheet, a "938G Series II Wheel Loader
and IT38G Series II Integrated Toolcarrier Power Train
Systems Operation Testing and Adjusting" manual, and
the correct tools, perform the tests and adjustments of the
power train hydraulic system according to the procedures
in the Service Manual during a lab exercise.

3. Given Lab C worksheet, a "938G Series II Wheel Loader

and IT38G Series II Integrated Toolcarrier Power Train
Systems Operation Testing and Adjusting" manual, and
the correct tools, perform the transmission clutch
engagement pressure calibration according to the
procedures in the Service Manual during a lab exercise.

4. Given Lab D worksheet, the "938G Series II Wheel Loader

and IT38G Series II Integrated Toolcarrier Power Train
Systems Operation Testing and Adjusting" manual, and a
938G Series II Wheel Loader and IT38G Series II
Integrated Toolcarrier Electrical Schematic, list the
locations and part numbers of power train electronic
control components on the worksheet during a lab
exercise.

(continued on next page)

Instructor(s):

________________________
Student
Student Average
Average Good
Good Excellent
Excellent
________________________ Student
Studentmet
metprerequisites
prerequisites

Training Manager: ClassParticipation

Class Participation

DesiretotoLearn
Desire Learn
________________________
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Objectives/Student Evaluation
Student Name: ________________________ Instructor(s):_______________________

Course Name: _________________________ Course Number: ___________________

Pretest Score: ________ Posttest Score: ____________

Instructor
Did student accomplish the following objectives? Additional remarks
Yes No

5. Given Lab E worksheet listing the power train operational

procedures and a 938G Series II Wheel Loader or IT38G
Series II Integrated Toolcarrier operate the machine and
record the results on the worksheet during a lab exercise.

6. Given Lab F worksheet, a "938G Series II Wheel Loader

and IT38G Series II Integrated Toolcarrier Power Train
Systems Operation Testing and Adjusting" manual, and
the correct tools, perform the calibration on the electronic
transmission control system according to the procedures
in the Service Manual during a lab exercise.

7. Given Lab G worksheet, a "938G Series II Wheel Loader

and IT38G Series II Integrated Toolcarrier Power Train
Systems Operation Testing and Adjusting" manual, and
the correct tools, perform the test on the shift lever
according to the procedures in the Service Manual during
a lab exercise.

8. Given Lab H worksheet, a "938G Series II Wheel Loader

and IT38G Series II Integrated Toolcarrier Power Train
Systems Operation Testing and Adjusting" manual, and
the correct tools, perform the left brake pedal position
sensor calibration according to the procedures in the
Service Manual during a lab exercise.

(continued on next page)

Instructor(s):

________________________
Student Average Good Excellent
________________________ Student met prerequisites

Training Manager: Class Participation

Desire to Learn
________________________
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Objectives/Student Evaluation
Student Name: ________________________ Instructor(s):_______________________

Course Name: _________________________ Course Number: ___________________

Pretest Score: ________ Posttest Score: ____________

Instructor
Did student accomplish the following objectives? Additional remarks
Yes No

9. Given a written case study, the case study worksheet,

and the appropriate service literature, complete a case
study focusing on the troubleshooting process.

10. Given a list of power train hydraulic system

components and a list of component functions, match
the component with the function during a posttest.

11. Given a list of power train electronic control system

components and a list of component functions, match
the component with the function during a posttest.

Instructor(s):

________________________
Student Average Good Excellent
________________________ Student met prerequisites

Training Manager: Class Participation

Desire to Learn
________________________
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Lesson Plan
Introduction 15 min
Discuss objectives and class schedule
Hand out and discuss student material

Lesson: Power Train Hydraulic System

Lesson consists of identification of the hydraulic components of the
power train system and performing testing and adjusting
procedures.

Visual Presentation 1: Power Train Hydraulic System 30 min

Lab A: Power Train Component Identification 35 min
Lab B: Power Train Hydraulic System Tests 60 min
Lab C: Transmission Clutch Engagement Pressure Calibration 30 min

Lesson: Power Train Electronic Control System

Lesson consists of identification of the electronic components of the
power train system and performing testing and adjusting
procedures.

Visual Presentation 2: Power Train Electronic Control System 20 min

Lab D: Power Train Electronic Control System
Component Identification 20 min
Lab E: ECM Operational Tests 60 min
Lab F: Transmission Clutch fill Calibration 40 min
Lab G: Transmission Control (Shift Lever) Test 20 min
Lab H: Left Brake Pedal Position Sensor Calibration 30 min

Case Study 30 min

Posttest: Power Train Hydraulic System Component and Functions 45 min

Administer posttest
Review and discuss posttest result

Posttest: Power Train Electronic System Component and Functions 45 min

Administer posttest
Review and discuss posttest result

Restore Machine 15 min

Total Estimated Time: 8 hours, 15 min

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Preparation Checklist
Prior to conducting the training session, gather and review the following materials:
__ 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power Train
Systems Operation Testing and Adjusting - RENR6066

__ Visual/Text Reference Materials

Each student should have one duplicated set of the following materials to use during classroom
presentations and for laboratory use. The materials listed below cover the 938G Series II Wheel Loader
and IT38G Series II Integrated Toolcarrier.
__ 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power
Train - SERV2739 (excluding Instructor Answer Key and Lab Guide)

Have at least one copy of the following materials available for student and instructor reference during
classroom presentations and laboratory use. The materials listed below cover 938G Series II Wheel
Loader and IT38G Series II Integrated Toolcarrier.
__ Service Manual (complete) - RENR6060

__ Operation and Maintenance Manual - SEBU7581

__ Parts Manual - SEBP3499

Have at least one copy of the following materials for each student.
__ 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power Train
Systems Operation Testing and Adjusting - RENR6066

__ Hydraulic System Schematic - RENR6079

__ Electrical System Schematic - RENR6082

__ Lab Worksheets
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Gather the following special tools and materials:

__ 938G Series II Wheel Loader or IT38G Series II Integrated Toolcarrier

__ Mechanic’s Tool Box with hand tools

__ Lettered or numbered tags for component identification (optional)

__ 1 - Digital Multimeter

__ 1 - 9U-7400 Multitach

__ 1 - 1U-5481 Pressure Gauge Group

__ 1-1U-5482 Hose and Fitting Group

__ 1 - Laptop PC (See NOTE)

__ 1 - "ET Service Tool Software/Getting Started" - JEBD3003

__ 1 - "ET Service Tool Software/User’s Manual" - NEHS0679

__ 1 - Communication Adapter II Group (171-4400)

NOTE:
Refer to the recommendations in the Booklet "ET Service Tool Software/Getting Started"
(JEBD3003) for a PC Laptop selection suitable for ET software.
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Visual/Text Reference
The Service Manual module "938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier
Power Train Systems Operation Testing and Adjusting" (RENR6066) must be used for preparation and
self study. The Lesson Plan serves as a guide through the Service Manual module.

There are multiple visual .pdf presentations. The visual presentation labeled "all visuals" contains every
visual represented in the Service Manual module "938G Series II Wheel Loader and IT38G Series II
Integrated Toolcarrier Power Train Systems Operation Testing and Adjusting" (RENR6066).

The remaining visual presentations contain the visuals needed for classroom instruction, and eliminate
duplicate visuals that are shown in Service Manual module. The instructor visuals are grouped into
individual files for each visual presentation. The following list identifies each visual presentation and its
corresponding topics from the Service Manual module. The illustrations within the topics are also
identified.

The visual presentations are:

Visual Presentation 1: Power Train Hydraulic System

Introduction and Features Illus. 1–13
Location of Hydraulic Components Illus. 29–39
Transmission Pump—Axle Oil Cooler Illus. 59–109

Visual Presentation 2: Power Train Electronic Control System

Location of Electrical Components Illus. 14–28
Electrical Input Components—Electrical Schematic (Transmission) Illus. 40–58
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Laboratory Exercises
The pages that follow provide lab exercises to reinforce the visual presentation. Instructions for
conducting the lab exercises are provided.

Lab exercises provide the student with an opportunity to locate and identify the system components and
perform testing and adjusting procedures on selected components and systems.

Some lab exercises are the written type with worksheets, while other labs are the traditional "on the iron"
labs. Some answers are provided for the worksheet exercise, while other labs reference the Testing and
Adjusting procedures of the System Operation/Testing and Adjusting Manual. Answers, when applicable,
are provided in the Instructor Answer Key and Lab Guide.

At the beginning of each lab, all students should review the lab description to be sure the students
understand what to do during the lab.

The labs are:

Lab A: Power Train Component Identification

Lab B: Power Train Hydraulic System Tests

Lab C: Transmission Clutch Engagement Pressure

Lab D: Power Train Electronic Control System Component Identification

Lab E: ECM Operational Tests

Lab F: Transmission Clutch Fill Calibration

Lab G: Transmission Control (Shift Lever) Test

Lab H: Left Brake Pedal Position Sensor Calibration

NOTE:
Discuss safety procedures with the students for each shop lab. (i.e. safety glasses, clothing).
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Lab A: Power Train Component Identification

Directions: Use this worksheet during the visual presentation to take notes on the function and machine
location of each component. During the lab exercise, place a check in the blank as each component is
identified on the machine. If letters or numbers are used for component identification enter it in the blank
instead. After locating the components use the Parts Manual or SIS to record the part name and number.

_____ 1. Torque converter

Location:

Function:

Parts Manual Name: ________________________________ Part Number:______________

_____ 2. Transmission

Location:

Function:

Parts Manual Name: ________________________________ Part Number:______________

_____ 3. Rear drive shaft

Location:

Function:

Parts Manual Name: ________________________________ Part Number:______________

_____ 4. Front drive shaft

Location:

Function:

Parts Manual Name: ________________________________ Part Number:______________

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_____ 5. Final drives

Location:

Function:

Parts Manual Name: ________________________________ Part Number:______________

_____ 6. Transmission oil reservoir

Location:

Function:

Parts Manual Name: ________________________________ Part Number:______________

_____ 7. Magnetic screen

Location:

Function:

Parts Manual Name: ________________________________ Part Number:______________

_____ 8. Transmission pump

Location:

Function:

Parts Manual Name: ________________________________ Part Number:______________

_____ 9. Transmission filter

Location:

Function:

Parts Manual Name: ________________________________ Part Number:______________

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_____ 10. Transmission proportional solenoid valves

Location:

Function:

Parts Manual Name: ________________________________ Part Number:______________

_____ 11. Transmission relief valve

Location:

Function:

Parts Manual Name: ________________________________ Part Number:______________

_____ 12. Torque converter inlet relief valve

Location:

Function:

Parts Manual Name: ________________________________ Part Number:______________

_____ 13. Torque converter outlet relief valve

Location:

Function:

Parts Manual Name: ________________________________ Part Number:______________

_____ 14. Transmission Cooler

Location:

Function:

Parts Manual Name: ________________________________ Part Number:______________

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Lab B: Power Train Hydraulic System Tests

Directions: Following the procedures in the "938G Series II Wheel Loader and IT38G Series II
Integrated Toolcarrier Power Train Systems Operation Testing and Adjusting" manual (RENR6066),
perform the torque converter stall test, transmission clutch pressure test, lubrication oil pressure test,
transmission pump pressure test, torque converter inlet pressure test, and solenoid valves test. Use this
worksheet to record system specifications and test results.

POWER TRAIN HYDRAULIC SYSTEM SPECIFICATION ACTUAL

Torque Converter Stall (rpm)

Torque Converter Inlet Pressure (kPa/psi)

Lubrication Pressure (kPa/psi)

Transmission Pump Pressure (kPa/psi)

NOTES:

Transmission Clutch Pressure Test (kPa/psi)

Clutch 1 Clutch 2 Clutch 3 Clutch 4 Clutch 5 Clutch 6
Specification
Actual
Pump Pressure

NOTES:
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SPEED RANGE AND WHICH WHICH If E.T. is available, record the

DIRECTION SOLENOIDS CLUTCHES following information:
ARE ON? ARE
ENGAGED? SOLENOID
Engine at LOW IDLE CURRENT %

Fourth Speed Forward

Third Speed Forward

Second Speed Forward

First Speed Forward

Neutral

First Speed Reverse

Second Speed Reverse

Third Speed Reverse

Fourth Speed Reverse

NOTES:
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Lab C: Transmission Clutch Engagement Pressure Calibration

Directions: Using the procedures in the "938G Series II Wheel Loader and IT38G Series II Integrated
Toolcarrier Power Train Systems Operation Testing and Adjusting" manual (RENR6066), perform the
transmission clutch engagement pressure calibration. Use this worksheet to record your results.

TRANSMISSION CLUTCH ENGAGEMENT PRESSURE CALIBRATION

YES NO
CALIBRATION
COMPLETED

FAULTS PRESENT

NOTES:
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Lab D: Power Train Electronic Control System Component

Identification

Directions: Use this worksheet during the visual presentation to take notes on the function and machine
location of each component. During the lab exercise, place a check in the blank as each component is
identified on the machine. If letters or numbers are used for component identification enter it in the blank
instead. After locating the components use the Parts Manual or SIS to record the part name and number.

_____ 1. Power Train Electronic Control Module (ECM)

Location:

Function:

Grid Location: _____________ Part Number:______________

_____ 2. Downshift switch

Location:

Function:

Grid Location: ______________ Part Number:______________

_____ 3. Solenoid for modulating valve

Location:

Function:

Grid Location: _____________ Part Number:______________

_____ 4. Left brake pedal position sensor

Location:

Function:

Grid Location: ______________ Part Number:______________

_____ 5. Transmission neutralizer override switch

Location

Function:

Grid Location: _____________ Part Number:______________

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_____ 6. Dash panel cluster

Location:

Function:

Grid Location: ____________ Part Number:______________

_____ 7. Transmission input speed sensor

Location:

Function:

Grid Location: _____________ Part Number:______________

_____ 8. Transmission intermediate speed sensor No. 1

Location:

Function:

Grid Location: ____________ Part Number:______________

_____ 9. Transmission intermediate speed sensor No. 2

Location:

Function:

Grid Location: ____________ Part Number:______________

_____ 10. Transmission output speed sensor No. 1

Location:

Function:

Grid Location: ____________ Part Number:______________

_____ 11. Transmission output speed sensor No. 2

Location:

Function:

Grid Location: ____________ Part Number:______________

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_____ 12. Autoshift switch

Location:

Function:

Grid Location: ______________ Part Number:______________

_____ 13. Engine ECM

Location

Function:

Grid Location: ____________ Part Number:______________

_____ 14. Variable shift control switch

Location:

Function:

Grid Location: ____________ Part Number:______________

_____ 15. Ride control switch

Location:

Function:

Grid Location: _____________ Part Number:______________

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Lab E: ECM Operational Tests

Directions: Before starting the machine: FASTEN SEAT BELT. Read and follow the instructions. The
gear shift position is shown in the LCD located in the dash instrument cluster.

1. Place the parking brake in the ENGAGED position, the auto/manual switch in the MANUAL position,
the neutralizer override switch in the OFF position, and the shift lever in the FIRST SPEED
FORWARD position. Start the machine.

Did the machine start? Yes:____ No: ____

2. Move the shift lever to the NEUTRAL position. Start the machine.

Did the machine start? Yes: ____ No:____

3. Place the shift lever in the FIRST NEUTRAL position and RELEASE the parking brake. Move the
shift lever to the FORWARD position. When the machine begins to move, ENGAGE the parking
brake.

Did the transmission shift to NEUTRAL? Yes: No:

4. ENGAGE the parking brake. Start the machine.

ENGAGE the service brakes throughout this test by pressing the right brake pedal.

Place the shift lever in THIRD FORWARD.

Did the transmission shift into gear?

Place the shift lever in NEUTRAL. Move the shift lever to FIRST FORWARD.

Did the transmission shift into gear?

Return the shift lever to NEUTRAL and then back into FIRST FORWARD. Did the transmission shift
into gear?

Explain the results:

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Lab F: Transmission Clutch Fill Calibration

Directions: Using the procedures in the "938G Series II Wheel Loader and IT38G Series II Integrated
Toolcarrier Power Train Systems Operation Testing and Adjusting" manual (RENR6066), perform the
transmission clutch fill calibration. Use this worksheet to record your results.

TRANSMISSION CLUTCH FILL CALIBRATION

YES NO
CALIBRATION
COMPLETED

FAULTS PRESENT

NOTES:
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Lab G: Transmission Control (Shift Lever) Test

Directions: Following the procedures in the "938G Series II Wheel Loader and IT38G Series II
Integrated Toolcarrier Power Train Systems Operation Testing and Adjusting" manual (RENR6066),
perform the transmission control (shift lever) test. Use this worksheet to record your results.

Transmission Shift Lever Position

Pin 1F 2F 3F 4F N 1R 2R 3R
1
2
3
4
5
6
7
8
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Lab H: Left Brake Pedal Position Sensor Calibration

Directions: Using the procedures in the "938G Series II Wheel Loader and IT38G Series II Integrated
Toolcarrier Power Train Systems Operation Testing and Adjusting" manual (RENR6066), perform the left
brake pedal position sensor calibration. Use this worksheet to record your results.

LEFT BRAKE PEDAL POSITION SENSOR CALIBRATION

YES NO
CALIBRATION
COMPLETED

FAULTS PRESENT

NOTES:
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Case Study
Directions: Students may use appropriate service literature and class notes to complete this case study.

Situation: The customer called the dealer and stated that a 938G Series II Wheel Loader would not shift
into FOURTH gear.

Gather Information: List at least three questions you would ask the operator.
1.

2.

3.

Verify: What would you do to verify that the problem exists. Operate the machine, if possible, to verify
the problem exists. Perform sensory checks such as looking, listening, touching, and smelling.

Perform Visual Inspection: When troubleshooting always perform a visual inspection first. Look for the
obvious. List at least three items that should be inspected during a visual inspection.
1.

2.

3.

State Problem: After verifying a problem exists, state in your own words what the problem is (not
solution).
1.

List Possible Faults: List possible causes of the problem. Identify systems and components that could
be causing the problem, including the obvious.

1.

2.

3.

Test to Determine Root Cause: List the tests that could be performed to find the root cause of the
problem.

1.

2.

Fix Machine: Perform tests if necessary and fix machine.

1.

Verify Repair: After completing the repair, always verify the machine is operating correctly.

1.
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Posttest: Power Train Hydraulic System Components

and Functions
Directions: Match each component to the correct function.

1. Torque converter A. Connects the output transfer gears to the

rear axle
2. Transmission
B. Provides the final torque increase of the
power to the wheels
3. Output transfer gear
C. Provides a hydraulic connection between
4. Rear drive shaft the engine and the transmission

D. Connects the output transfer gears to the

5. Front drive shaft
front axle

6. Final drives E. Provides speed and directional conversion

of the available engine power
7. Transmission oil reservoir
F. Transmission oil supply stored in the
bottom of the transfer gear case
8. Magnetic screen
G. Lowers the power flow from the
9. Transmission pump transmission to the axles

H. Removes metal particles from the supply

10. Transmission filter oil

11. Transmission proportional solenoid I. Filters the oil from the transmission pump
valves to the transmission hydraulic system

J. Supplies oil flow to the transmission

12. Transmission relief valve hydraulic system

13. Torque converter inlet relief valve
14. Torque converter outlet relief valve
15. Cooler
K. Limits the oil pressure to the proportional
solenoid valves
L. Maintains the pressure in the torque
converter
M. Controls oil pressure in a clutch

N. Cools the transmission hydraulic oil

O. Limits the pressure to the torque converter

SERV2739
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Posttest: Power Train Electronic Control System
Components and Functions
Directions: Match each component to the correct function.
1. Transmission electronic control
module
2. Transmission neutralizer switch
3. Auto/manual switch
4. Downshift switch
5. Engine speed sensor
6. Transmission input speed sensor
7. Transmission intermediate speed
sensor No. 1
8. Transmission intermediate speed
sensor No. 2
9. Transmission output speed sensor
No. 1
10. Transmission output speed sensor
No. 2
11. Transmission oil temperature sensor
12. Key start switch
13. Transmission proportional solenoid
valves
14. Transmission neutralizer override
switch
15. Left brake pedal position sensor
27 938G Series II and IT38G Series II
iTIM for RENR6066
A. Signals the ECM when to energize the
engine starter relay
B. Neutralizes the transmission when
operator DEPRESSES the left brake
pedal
C. Allows the operator to manually
downshift the transmission
D. Measures transmission input speed
E. Receives sensor and switch inputs and
controls transmission shifting, engine
starting, ride control and secondary
steering
F. Signals the ECM the shift mode in
which the operator wants to operate
G. Identifies the direction of travel
H. Controls oil flow and pressure to the
clutches
I. Measures transmission intermediate
speed
J. Measures transmission output speed
K. Measures transmission oil temperature
L. Measures engine speed
M. When in the ON position, signals the
ECM that the operator wants to
override the service brake neutralizer
switch on the left brake pedal.
N. Identifies the direction of travel
O. Provides a signal to the Power Train
ECM to neutralize the transmission
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Instructor Answer Key and Lab Guide

The following section contains answers to the lab exercises, case study, and posttest. Some lab
exercises do not have a specific answer and are represented by NA (not applicable). Review and
perform the labs before delivering this module.

For component identification lab exercises, the instructor should fill in the part name and part number
prior to the class. For testing and adjusting lab exercises, the instructor should record the test
specifications prior to class. Because part numbers and specifications can change, these values should
be confirmed prior to each class.

For testing and adjusting lab exercises, students should use SIS or the appropriate service literature to
record the test specifications before completing the lab exercise. At the completion of the lab exercise,
review the results to make sure that all students achieved the same or similar results.

Lab A: Power Train Component Identification

Lab Notes:
The instructor should fill in the blanks for the Parts Manual Name and Part Number prior to assigning that
portion of the lab to the students as either an in class or homework assignment.
The instructor may chose to use tags marked with letters or numbers on the iron for less skilled students.
The student should enter the letter or number in the blank if this technique is used. The instructor must
allow additional preparation time to remove sheet metal, place the tags on the components, and record
the answers in the answer key.
Explain the process for filling out the worksheets (distributed during the slide presentation).

Materials Needed:
____ Lettered or numbered tags (optional)

____ Lab A worksheets

____ Pen or pencil

____ 938G Series II Wheel Loader or IT38G Series II Integrated Toolcarrier

____ Mechanic's tool box with hand tools

Answers:
_____ 1. Torque converter
Location: Located below the rear of the cab between the engine and transmission
Function: Provides a hydraulic connection between the engine and the transmission
Parts Manual Name: ________________________________ Part Number:______________

_____ 2. Transmission
Location: Below the cab
Function: Provides speed and directional conversion of the available engine power
Parts Manual Name: ________________________________ Part Number:______________
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_____ 3. Rear drive shaft

Location: Located between the rear axle and the transmission
Function: Connects the output transfer gears to the rear axle
Parts Manual Name: ________________________________ Part Number:______________

_____ 4. Front drive shaft

Location: Located between the front axle and the transmission
Function: Connects the output transfer gears to the front axle
Parts Manual Name: ________________________________ Part Number:______________

_____ 5. Final drives

Location: Located in the front and rear axles
Function: Provides the final torque increase of the power to the wheels
Parts Manual Name: ________________________________ Part Number:______________

_____ 6. Transmission oil reservoir

Location: At the bottom of the transfer gear case
Function: Power train oil supply stored in the bottom of the transfer gear case
Parts Manual Name: ________________________________ Part Number:______________

_____ 7. Magnetic screen

Location: Located on the transmission case next to the rear drive shaft connection
Function: Removes metal particles from the supply oil
Parts Manual Name: ________________________________ Part Number:______________

_____ 8. Transmission pump

Location: Located beneath the cab behind the left cab access ladder
Function: Supplies oil flow to the transmission hydraulic system
Parts Manual Name: ________________________________ Part Number:______________

_____ 9. Transmission filter

Location: Located on the left side of the machine behind the cab access ladder
Function: Filters the oil from the transmission pump to the transmission hydraulic system
Parts Manual Name: ________________________________ Part Number:______________

_____ 10. Transmission proportional solenoid valves

Location: Located on the top of the transmission housing on the right side of the machine
Function: Control oil pressure in the clutches
Parts Manual Name: ________________________________ Part Number:______________
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_____ 11. Transmission relief valve

Location: Located on the top of the transmission housing on the right side of the machine
Function: Limits oil pressure to the transmission proportional solenoid valves
Parts Manual Name: ________________________________ Part Number:______________

_____ 12. Torque converter inlet relief valve

Location: Located on the top of the transmission housing on the right side of the machine
Function: Limits the pressure to the torque converter
Parts Manual Name: ________________________________ Part Number:______________

_____ 13. Torque converter outlet relief valve

Location: Located on the top of the transmission housing on the right side of the machine
Function: Maintains the pressure in the torque converter
Parts Manual Name: ________________________________ Part Number:______________

_____ 14. Transmission Cooler

Location: Located under the right engine enclosure between the hydraulic oil cooler and ATAAC
Function: Cools the transmission hydraulic oil
Parts Manual Name: ________________________________ Part Number:______________
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Lab B: Power Train Hydraulic System Tests

Lab Notes:
During this lab exercise, the students will follow the procedures in the "938G Series II Wheel Loader and
IT38G Series II Integrated Toolcarrier Power Train Systems Operation Testing and Adjusting" manual
(RENR6066) to perform the following tasks on the power train hydraulic system and record the
information on the lab worksheet:

1. Torque converter stall test

2. Transmission clutch pressure test

3. Lubrication oil pressure test

4. Transmission pump pressure test

5. Torque converter inlet pressure test

6. Test for the solenoid valves

Materials Needed:
__ Lab B worksheet

__ 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power Train
Systems Operation Testing and Adjusting manual (RENR6066)

__ 1U-5481 Pressure Gauge Group

__ 1U-5482 Hose and Fitting Group

__ 9U-7400 Multitach

__ 938G Series II Wheel Loader or IT38G Series II Integrated Toolcarrier

Answers:
The instructor should record the test specifications prior to class. Check the "938G Series II Wheel
Loader and IT38G Series II Integrated Toolcarrier Power Train Systems Operation Testing and Adjusting"
manual (RENR6066) for current specifications for all tests. Because specifications can change, these
values should be confirmed prior to each class.
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Lab C: Transmission Clutch Fill Calibration

Lab Notes:
During this lab exercise, the students will follow the procedures in the "938G Series II Wheel Loader and
IT38G Series II Integrated Toolcarrier Power Train Systems Operation Testing and Adjusting" manual
(RENR6066) to perform the transmission clutch engagement pressure calibration.

Materials Needed:
__ Lab C worksheet

__ 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power Train
Systems Operation Testing and Adjusting (RENR6066)

__ 938G Series II Wheel Loader or IT38G Series II Integrated Toolcarrier

__ PC Laptop Computer

__ "ET Service Tool Software/Getting Started" - JEBD3003

__ "ET Service Tool Software/User’s Manual" - NEHS0679

__ Communication Adapter II Group (171-4400)

Answers:
The Transmission Clutch Engagement Pressure Calibration is a pass or fail procedure.
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Lab D: Power Train Electronic Control System Component Identification

Lab Notes:
During this lab exercise, the students will identify the Power Train Electronic Control System components
by schematic grid location and part number and record this information on the worksheets. The instructor
should fill in the part name and part number prior to the class. Because part numbers and schematic
locations can change, these values should be confirmed prior to each class.

Instructor provides 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Electrical
Schematic showing the Power Train Electronic Control System components. Explain the process for
filling out the worksheets (distributed during the slide presentation).

Materials Needed:
__ 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Electrical
Schematic - (RENR6434)

__ Lab D worksheets

__ Pen or pencil

Answers:
_____ 1. Power Train Electronic Control Module (ECM)
Location: Located under the platform outside the right cab door
Function: Receives sensor and switch input signals and controls transmission shifting, engine
starting, ride control and secondary steering
Grid Location: _____________ Part Number:______________

_____ 2. Downshift switch

Location: Located on the lift control lever
Function: Allows the operator to manually downshift the transmission
Grid Location: ______________ Part Number:______________

_____ 3. Solenoid for modulating valve

Location: Located on each modulating valve
Function: Receives signal from ECM and shifts the spool in modulating valve to allow
pressurized oil to a clutch
Grid Location: ____________ Part Number:______________

_____ 4. Left brake pedal position sensor

Location: Located in housing at base of the left brake pedal
Function: Provides a signal to the Machine ECM to neutralize the transmission when the left
brake pedal is engaged
Grid Location: ______________ Part Number:______________
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_____ 5. Transmission neutralizer override switch

Location: Located on the switch panel to the right of the operator seat
Function: In the ON position, signals the ECM that the operator wants to eliminate the left brake
pedal transmission neutralizer function
Grid Location: _____________ Part Number:______________

_____ 6. Dash panel cluster

Location: Located behind the steering wheel
Function: Receives and displays ECM information in a centralized location
Grid Location: _____________ Part Number:______________

_____ 7. Transmission input speed sensor

Location: Located on the transmission housing between the ECPC control valve and the engine
Function: Measures transmission input speed
Grid Location: _____________ Part Number:______________

_____ 8. Transmission intermediate speed sensor No. 1

Location: Located on the transmission housing below the ECPC control valve
Function: Measures transmission intermediate speed
Grid Location: ____________ Part Number:______________

_____ 9. Transmission intermediate speed sensor No. 2

Location: Located on the transmission housing below the ECPC control valve
Function: Identifies the direction of travel
Grid Location: ____________ Part Number:______________

_____ 10. Transmission output speed sensor No. 1

Location: Located on the transmission housing below the ECPC control valve
Function: Measures transmission output speed
Grid Location: ____________ Part Number:______________

_____ 11. Transmission output speed sensor No. 2

Location: Located on the transmission housing below the ECPC control valve
Function: Identifies the direction of travel
Grid Location: ____________ Part Number:______________

____ 12. Autoshift switch

Location: Located on the left dash panel
Function: Signals the ECM the shift mode in which the operator wants to operate
Grid Location: ______________ Part Number:______________
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____ 13. Engine ECM

Location: Located on the engine behind the breaker panel on the right side of the machine
Function: Monitors engine data and communicates information to the Power Train ECM
Grid Location: ____________ Part Number:______________

___ 14. Variable shift control switch

Location: Located on the right dash panel
Function: Allows operator to change autoshift points relative to engine rpm
Grid Location: _____________ Part Number:______________

_____ 15. Ride control switch

Location: Located on the switch panel to the right of the operator seat
Function: Signals the ECM that the operator wants to select one of three ride control modes
Grid Location: _____________ Part Number:______________
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Lab E: ECM Operational Tests

Lab Notes:
During this lab exercise, the students will operate the machine and complete the worksheet. Discuss
results after all students have completed the tests.

Materials Needed:
__ Lab E worksheets

__ 938G Series II Wheel Loader or IT38G Series II Integrated Toolcarrier

__ Pen or pencil

Answers:
1. Place the parking brake in the ON position, the auto/manual switch in the MANUAL position, the
neutralizer override switch in the OFF position, and the shift lever in the FIRST SPEED FORWARD
position. Start the machine.

Did the machine start? Yes: No: X The Power Train ECM will not allow the machine to
start while the shift lever is in gear.

2. Move the shift lever to the NEUTRAL position. Start the machine.

Did the machine start? Yes: X No: The ECM allows the machine to start with the shift
lever in NEUTRAL.

3. Place the shift lever in the FIRST NEUTRAL position and RELEASE the parking brake. Move the
shift lever to the FORWARD position. When the machine begins to move, ENGAGE the parking
brake.

Did the transmission shift to NEUTRAL? Yes: X No: The ECM will shift the transmission
to NEUTRAL when the parking brake is applied.

4. ENGAGE the parking brake. Start the machine.

ENGAGE the service brakes throughout this test by pressing the right brake pedal.

Place the shift lever in THIRD FORWARD.

Did the transmission shift into gear? YES

Place the shift lever in NEUTRAL. Move the shift lever to FIRST FORWARD.

Did the transmission shift into gear? NO

Return the shift lever to NEUTRAL and then back into FIRST FORWARD. Did the transmission shift
into gear? YES

Explain the results: The ECM will allow SECOND, THIRD, and FOURTH gears to engage when the
paring brake is ENGAGED. The ECM will not allow FIRST gear to engage while the parking brake
is ENGAGED unless the shift lever is moved into FORWARD, returned to NEUTRAL, and moved
again into FORWARD.
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Lab F: Transmission Clutch Fill Calibration

Lab Notes:
During this lab exercise, the students will follow the procedures in the "938G Series II Wheel Loader and
IT38G Series II Integrated Toolcarrier Power Train Systems Operation Testing and Adjusting" manual
(RENR6066) to perform the transmission fill calibration.

Materials Needed:
__ Lab F worksheet

__ 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power Train
Systems Operation Testing and Adjusting (RENR6066)

__ 938G Series II Wheel Loader or IT38G Series II Integrated Toolcarrier

__ PC Laptop Computer

__ "ET Service Tool Software/Getting Started" - JEBD3003

__ "ET Service Tool Software/User’s Manual" - NEHS0679

__ Communication Adapter II Group (171-4400)

Answers:
The Transmission Clutch Fill Calibration is a pass or fail procedure.
SERV2739 38 938G Series II and IT38G Series II
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Lab G: Transmission Control (Shift Lever) Test

Lab Notes:
During this lab exercise, the students will follow the procedures in the "938G Series II Wheel Loader and
IT38G Series II Integrated Toolcarrier Power Train Systems Operation Testing and Adjusting" manual
(RENR6066) to perform the transmission control (shift lever) test. Instruct the students to fill in the table
with their results according to the instructions in the manual.

Materials Needed:
__ Lab G worksheet

__ 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power Train
Systems Operation Testing and Adjusting (RENR6066)

__ 938G Series II Wheel Loader or IT38G Series II Integrated Toolcarrier

__ Digital Multimeter

Answers:
Check the "938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power Train Systems
Operation Testing and Adjusting" manual (RENR6066) for correct results to fill in the table.
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Lab H: Left Brake Pedal Position Sensor Calibration

Lab Notes:
During this lab exercise, the students will follow the procedures in the "938G Series II Wheel Loader and
IT38G Series II Integrated Toolcarrier Power Train Systems Operation Testing and Adjusting" manual
(RENR6066) to perform the left brake pedal position sensor calibration.

Materials Needed:
__ Lab H worksheet

__ 938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power Train
Systems Operation Testing and Adjusting (RENR6066)

__ 938G Series II Wheel Loader or IT38G Series II Integrated Toolcarrier

__ 1U-5481 Pressure Gauge Group

__ 1U-5482 Hose and Fitting Group

__ PC Laptop Computer

__ "ET Service Tool Software/Getting Started" - JEBD3003

__ "ET Service Tool Software/User’s Manual" - NEHS0679

__ Communication Adapter II Group (171-4400)

Answers:
The Left Brake Pedal Position Sensor Calibration is a pass or fail procedure.
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Case Study
Case Study Notes:

The case study provides an opportunity for students to apply their knowledge of the power train system in
a simulated service call. The case study should be completed as a group exercise. The instructor should
facilitate a discussion that focuses on the troubleshooting process, not the students ability to solve the
problem. The following answers are suggestions only. There may be other correct answers.

The mechanic connects ET to the machine. The mechanic selects the Power Train ECM and verifies that
there are no active or logged faults. Knowing that machine features and functions can be changed,
enabled, and disabled on the configuration screen in ET, the mechanic checks the Power Train ECM
configuration screen to verify that the power train parameters are set as desired. The configuration
screen shows that the Transmission Maximum Forward Gear is set at 3. The mechanic selects the
Transmission Maximum Forward Gear and changes the value to 4. The machine is operated and
verification is made that the transmission shifts into FOURTH gear.

Gather Information: List at least three questions you would ask the operator.
1. Did any alert indicators come on?

2. Was there any unusual sounds when the machine was started?

3. Has this been an ongoing problem or did it start all at once?

Verify: Operate the machine, if possible, to verify the problem exists. Watch the fan blade when the
reversing fan is depressed and verify that the fan does not reverse directions.

Perform Visual Inspection: When troubleshooting always perform a visual inspection first. Look for the
obvious. List at least three items that should be inspected during a visual inspection.

1. Look for activated alert indicators and fault codes on the dash instrument cluster.

2. Check for loose or bad wiring.

3. Check for hydraulic oil leaks.

State Problem: The machine will not go into FOURTH gear.

List Possible Faults: List possible causes of the problem. Identify systems and components that could
be causing the problem, including the obvious.

1. A proportional solenoid valve may be malfunctioning.

2. The signal from the shift lever is not being received by the ECM.

3. The Machine ECM may not be programmed correctly.

Test to Determine Root Cause: List the tests that could be performed to find the root cause of the
problem.

1. Check the Machine ECM configuration screen to see if FOURTH gear is enabled.

2. Check pressures on the proportional solenoid valves for FOURTH and FORWARD.
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Fix Machine: Perform tests if necessary and fix machine.

1. Change the value of the maximum forward speed to 4 on the ECM configuration screen.

Verify Repair: After completing the repair, always verify the machine is operating correctly.

1. Operate the machine and verify that the transmission shifts into FOURTH gear.

Posttest: Power Train Hydraulic Components and Functions

Posttest Notes:
Inform students that they may refer to the Service Manual or class notes while taking the quiz. Inform
students that they may not confer among themselves. Discuss completed quiz with class.

1. C

2. E

3. G

4. A

5. D

6. B

7. F

8. H

9. J

10. I

11. M

12. K

13. O

14. L

15. N
SERV2739 42 938G Series II and IT38G Series II
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Posttest: Power Train Electronic Control System Components and Functions

Posttest Notes:
Inform students that they may refer to the Service Manual or class notes while taking the quiz. Inform
students that they may not confer among themselves. Discuss completed quiz with class. Some
questions may have more than one correct answer.

1. E

2. B

3. F

4. C

5. L

6. D

7. I

8. N or G

9. J

10. G or N

11. K

12. A

13. H

14. M

15. O