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7/4/2019 793D Off-Highway Truck FDB00001-UP (MACHINE) POWERED BY 3516B Engine(SEBP3976 - 206) - Systems & Components

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Welcome: r080crc15
Product: TRUCK
Model: 793D TRUCK FDB
Configuration: 793D Off-Highway Truck FDB00001-UP (MACHINE)
POWERED BY 3516B Engine

Testing and Adjusting


793D Off-Highway Truck Power Train
Media Number -RENR8327-05 Publication Date -01/04/2015 Date Updated -07/08/2018

i02410588

Torque Converter and Transmission Hydraulic System


Troubleshooting
SMCS - 3000; 3101

Personal injury or death can result from sudden machine movement.

Sudden movement of the machine or release of air pressure or oil


pressure can cause injury to persons on or near the machine.

To help prevent possible injury before testing and adjusting any air
system or hydraulic system, perform the procedure in the Testing and
Adjusting, "General Information" section.

Perform the visual checks before you troubleshoot a problem. Make sure that the transmission is in neutral and
stop the engine. During the visual checks, use a magnet to separate ferrous particles (iron and steel) from
nonferrous particles (aluminum, rubber and paper).

Note: If any of the particles that are listed in the checks are found during a visual check, all the components of
the torque converter and the transmission systems must be cleaned. Do not use any damaged parts. Damaged
parts must be removed and new parts must be installed.

Check: Check the oil level in the torque converter sump


Check the oil level in the torque converter sump. Look for air or for water at the sight gauge. Many problems in
the torque converter and in the transmission are caused by low oil levels or by air in the oil. Add oil to the torque
converter sump, if necessary. See the Operation and Maintenance Manual for the correct type of oil.

Problem: There is an indication of water in the oil.

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Illustration 1 g00290393
Right side of the engine
(1) Oil cooler for the torque converter and the transmission

Probable Cause

Failure of oil cooler (1) for the torque converter and the transmission

Problem: There is an indication of air in the oil.

Probable Cause

There is leakage in the system. See "Check: Check for oil leakage".

The oil level in the torque converter sump is too high or too low.

Problem: The oil level is too low.

Probable Cause

There is leakage from the system. See "Check: Check for oil leakage". Add oil before any tests are
performed.

Problem: The oil level is too high.


Probable Cause

The engine crankshaft rear seal is allowing engine oil into the torque converter cover.

The oil from the differential and bevel gear leaks into the transmission case. One potential reason for the
leaks is the failure of the pinion seal in the differential. The leaks can also occur if the center plug of the
differential pinion is not installed or if the pinion leaks.

The pump shaft seal for one or more of the pumps that is fastened to the pump drive has failed. Oil from
the pump is leaking through the pump drive into the transmission sump.

Check: Check for oil leakage


Inspect all the oil lines, the hoses, and the connections for damage or for leaks. Look for oil on the ground under
the machine.

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Note: If oil can leak out of a fitting or a connection, air can enter the system. Air in the system can be as harmful
as not enough oil.

Check: Check the transmission charging hydraulic filter

Illustration 2 g01211786
(2) Transmission charging hydraulic filter

Remove transmission charging hydraulic filter (2). Inspect the filter for foreign material.

Note: The transmission charging hydraulic filter has a bypass valve. A bypass valve allows oil to bypass the oil
filter element whenever the pressure difference between the inlet oil and the outlet oil at the oil filter gets too
high. Any oil that does not go through the filter element flows directly into the hydraulic circuit. Dirty oil causes
restrictions in valve orifices and in sticking valves.

The differential pressure setting of the bypass valve in transmission charging hydraulic filter (2) is
approximately 345 kPa (50 psi).

Problem: Rubber particles are found.


Probable Cause

Seal failure

Hose failure

Problem: Shiny steel particles are found.

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Illustration 3 g01204793
Transmission and torque converter gear pump
(3) Transmission lubrication section
(4) Transmission charging pump section
(5) Torque converter charging pump section
(6) Transmission scavenge pump section

Probable Cause

Mechanical failure of transmission charging pump section (4)

Check: Check the torque converter hydraulic filter

Illustration 4 g01204818
(7) Torque converter hydraulic filter

Remove torque converter hydraulic filter (7). Inspect the filter for foreign material.

Note: Torque converter hydraulic filter (7) has a bypass valve. A bypass valve allows oil to bypass the oil filter
element whenever the pressure difference between the inlet oil and the outlet oil at the oil filter gets too high.
Any oil that does not go through the filter element flows directly into the hydraulic circuit. Dirty oil causes
restrictions in valve orifices and in sticking valves.
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The differential pressure setting of the bypass valve in torque converter hydraulic filter (7) is approximately
127 kPa (18 psi).

Problem: Rubber particles are found.


Probable Cause

Seal failure

Hose failure

Problem: Shiny steel particles are found.

Illustration 5 g01204793
Transmission and torque converter gear pump
(3) Transmission lubrication section
(4) Transmission charging pump section
(5) Torque converter charging pump section
(6) Transmission scavenge pump section

Probable Cause

Mechanical failure of torque converter charging pump section (5)

Check: Check the transmission magnetic screens

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Illustration 6 g00290397
Lower right side of the transmission case
(8) Transmission magnetic screens inside the case

Remove transmission magnetic screens (8). Inspect transmission magnetic screens (8) for foreign material
and/or for restrictions.

Problem: Rubber particles are found.

Probable Cause

Seal failure

Hose failure

Problem: Black fiber is found.

Probable Cause

Worn clutches in the transmission

Problem: Iron chips or steel chips are found.

Probable Cause

Broken components in the transfer gears or in the transmission

Problem: Aluminum particles are found.


Probable Cause

Worn housings, load pistons, or selector pistons in the pressure control valve

Check: Check the torque converter screen

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Illustration 7 g00290398
Left side of the torque converter
(9) Torque converter screen

Remove torque converter screen (9). Inspect the screen for foreign material.

Problem: Rubber particles are found.

Probable Cause

Seal failure

Hose failure

Problem: Shiny steel particles are found.

Illustration 8 g01204793
Transmission and torque converter gear pump
(3) Transmission lubrication section
(4) Transmission charging pump section
(5) Torque converter charging pump section
(6) Transmission scavenge pump section

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Probable Cause

There is a mechanical failure of torque converter charging pump section (5). Perform the check in "Check:
Check the torque converter hydraulic filter".

Problem: A large quantity of aluminum particles are found.


Probable Cause

Mechanical failure of the torque converter

Problem: Black fiber is found.

Probable Cause

A worn lockup clutch in the torque converter

Check: Check inside the transmission case

Illustration 9 g00290399
(10) Transmission drain plugs

Remove plugs (10) in the bottom of the transmission case. This will drain all the oil out of the transmission and
the transfer gears. Measure the total amount of the oil that is removed at both plugs. Inspect the oil for foreign
material.

Problem: More than 76 L (20 US gal) of oil is drained.

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Illustration 10 g01204793
Transmission and torque converter gear pump
(3) Transmission lubrication section
(4) Transmission charging pump section
(5) Torque converter charging pump section
(6) Transmission scavenge pump section

Illustration 11 g00290397
Lower right side of the transmission case
(8) Transmission magnetic screens inside the case

Probable Cause

Failure of the transmission scavenge pump section (6)

Restriction in transmission magnetic screens (8)

Too much leakage in a transmission clutch

Problem: Iron chips or steel chips are found.

Probable Cause

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Broken components in the transfer gears or in the transmission

Problem: Aluminum particles are found.


Probable Cause

Worn housings, worn load pistons, or worn selector pistons in the pressure control valve

Check: Check inside the torque converter sump

Illustration 12 g01204817
Torque converter sump
(11) Cover for the suction screen

Drain the oil from the torque converter sump. Remove cover (11). Remove the suction screen. Clean the suction
screen.

Problem: Rubber particles are found.

Probable Cause

Seal failure

Hose failure

Problem: Shiny steel particles are found.

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Illustration 13 g01204793
Transmission and torque converter gear pump
(3) Transmission lubrication section
(4) Transmission charging pump section
(5) Torque converter charging pump section
(6) Transmission scavenge pump section

Illustration 14 g00290401
(12) Pump drive

Problem: Shiny steel particles are found.

Probable Cause

A worn drive gear or a worn driven gear on torque converter charging pump section (5)

Mechanical failure of the transmission scavenge pump section (6)

There is a mechanical failure of pump drive (12). Drain the pump drive. Inspect the oil pump drive.

There is a worn flywheel or a worn starter motor pinion gear on the engine. Inspect the starter motor
pinion gear and the flywheel gear.

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Overheated Transmission Hydraulic System


An overheating condition in the hydraulic system will probably be first detected through Vital Information
Management Systems (VIMS). The temperature sensor for the torque converter is located near the torque
converter screen. The temperature sensor for the transmission lubrication oil is located at the entrance of the oil
into the transfer gears. Both the sensors provide input signals to the VIMS.

Probable Cause

Illustration 15 g00290393
Right side of the engine
(1) Oil cooler for the torque converter and the transmission

Restriction in oil cooler (1) for the torque converter and the transmission

Illustration 16 g01204793
Transmission and torque converter gear pump
(3) Transmission lubrication section
(4) Transmission charging pump section
(5) Torque converter charging pump section
(6) Transmission scavenge pump section

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Failure in any section of the oil pump for the transmission and the torque converter. Perform the checks in
"Check: Check the torque converter hydraulic filter" and in "Check: Check the transmission charging
hydraulic filter".

There may be a restriction in one of the hose assemblies.

The machine is operating too long in torque converter drive with an extreme load.

Copyright 1993 - 2019 Caterpillar Inc. Sun Apr 07 2019 16:51:52 GMT-0500 (hora estándar de Perú)
All Rights Reserved.
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