caterpillar 920 wheel loader power train problem

[upali1980@r]

I have a cat 920 wheel loader.I replaced clutch disc and i repaired.because of its power has lost suddenly. i found the reason.there was a broken spring in the pressure control valve.so i put a new one.the problem is loader has no much power. other thing is transmission oil color is getting dark and temperature reaching high.
can anyone give me a pressure setting catalog of a cat 920.
please i appreciate any help.
thank.

 

[Per Eriksson]

Seems like you aren't getting enough flow to the converter.
Which spring was broken in the control body?

Do you have an emailadress I can send a pdf to?

 

[upali1980@r]

thank u per eriksson.
yes my email is upaliyapa1980@mail.com or upaabesinghe@gmail.com

the spring which was broken is in the modulating relief valve.it is outside spring.
i have D4E power shift transmission testing and adjusting catalog.I'll mark the spring and send u.

 

[upali1980@r]

thank u Per Eriksson. I got your mail and sent u D4E catalog.I'm connecting with this forum and I'll write the result.

 

[upali1980@r]

today i check pressures
pump 3.47kg/cm2(g/c minimum) 10.2kg/cm2(g/c max)
speed clutch primary setting 3.5 kg/cm2
direction clutch 1 kg/cm2 (g/c minimum) 7 kg/cm2(g/c max)
inlet to the torque convertor 2 kg/cm2 (selector lever in neutral ) 1 kg/cm2 ( selector lever in 1st forward)

what should i do.
please i need more help

 

[Per Eriksson]

I would take the pump apart and check it for wear.

 

[upali1980@r]

thank you Per Eriksson.
today I'll try to check the speed clutch pressure g/c lever at max setting.

 

[upali1980@r]

the oil pressure of speed clutch (g/c lever at max) is 10.4 kg/cm2.
I like to check lubrication relief valve.please can you tell me where it is the location.

 

[Per Eriksson]

Lube oil is the return from cooler/torque converter, doesn't have any relief.

 

[upali1980@r]

In the catalog that you have sent me page 2 of 8 shows it by number 8 called 'lubrication relief valve'
other thing why dose pressure of direction clutch go to 7 kg/cm2(g/c at max). it should be 3.5 kg/cm2.so i think there should be a problem in the pressure control valve.
please could you explain me.

 

[Per Eriksson]

No, direction clutch pressure shyould be 3,5 bar LESS than the speed clutch pressure so about 15bar at idle.

You either have very bad flow from the pump or a big leak in the controlvalve. since all pressures are too low.

 

[upali1980@r]

thank you per eriksson. I'll disassemble the pump and send you its images.

 

[upali1980@r]

Dear my friend.
I did a little bit different experiment. I keep the engine rpm at about 1000 and close the tap step by step to increase the pressure .but I couldn't get the pressure to bar 5 even by closing the tap full.after that i removed the pump off and disassembled.

 

[upali1980@r]

 

[upali1980@r]

 

[upali1980@r]

 

[upali1980@r]

 

[upali1980@r]

 

[upali1980@r]

 

[upali1980@r]