Bench Test Procedure For A 416C, 416D, 420D, 424D, 426C, 428D, 430D, 432D, 436C, 438D, and 442D Backhoe Loader Transmission (Standard Shift) {3030, 3174} Caterpillar

Bench Test Procedure For A 416C, 416D, 420D, 424D, 426C, 428D, 430D, 432D, 436C, 438D, and 442D Backhoe Loader Transmission (Standard Shift) {3030, 3174}

Usage:

426C 1CR

Backhoe Loader: 416C (S/N: 4ZN1-UP; 1WR1-UP); 416D (S/N: BKG1-UP; BGJ1-UP; BFP1-UP; CXP1-UP); 420D (S/N: BKC1-UP; BMC1-UP; BLN1-UP; FDP1-UP); 424D (S/N: RXA1-UP; BGP1-UP; BKR1-UP; CJZ1-UP); 426C (S/N: 6XN1-UP; 1CR1-UP; 1MR1-UP; 1YR1-UP); 428D (S/N: BNB1-UP; BLL1-UP; MBM1-UP; BNS1-UP; BMT1-UP; DSX1-UP); 430D (S/N: BNK1-UP; BML1-UP); 432D (S/N: WEP1-UP; TDR1-UP); 436C (S/N: 8TN1-UP; 1FR1-UP; 1PR1-UP; 2AR1-UP); 438D (S/N: BPE1-UP; BPN1-UP); 442D (S/N: TBD1-UP; BRG1-UP; SMJ1-UP; BRY1-UP)

Introduction

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Table 1
Revision	Summary of Changes in REHS1669
05	Modified Table 3CRB 236-4489 with 484-2106.
04	Standardized.
03	Added new Introduction and Canceled Part Numbers section.

© 2017 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This special instruction contains the necessary information that is required to bench test-specific transmission arrangements. Refer to Table 2 for the correct arrangements. Bench testing the transmission ensures correct assembly and operation of the component. Rotating a transmission provides the most conclusive evaluation. This allows the dealer to ensure that the transmission will operate properly in the machine. The specifications in this guideline are specific to bench testing the component. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

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Table 2
Machine Model	Transmission Arrangement
416C	107-3762
416D	185-7586
420D	185-7586
424D	185-7586, 185-7585
426C	107-3762
428D	185-7586
430D	185-7586
432D	185-7586
436C	107-3762
438D	185-7586
442D	185-7586

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

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Illustration 1	g02139237

Follow all safety warnings. Most accidents that involve product operation, maintenance, or repair are caused by failure to observe safety warnings. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. Personnel must be properly trained to perform maintenance, repair, or operate any machine. Safety precautions and warnings are provided this instruction and on Caterpillar products. These warnings should be observed before performing any procedures. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are not all inclusive.

The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word” such as “DANGER”, “WARNING, or” “CAUTION”. The “WARNING” Safety Alert Symbol is shown in illustration below.

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Illustration 2	g00008666

This safety alert symbol means:

Pay Attention!

Become Alert!

Your Safety is Involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Collecting the Test Data

Since conditions vary for each test bench, use the data that is collected from your test bench. The collected data is used to compare test results. The data should be collected and maintained by the operator.

Data from each transmission arrangement is collected and stored. Averages from each transmission arrangement are often used to compare values on portions of transmission tests. Always compare data that is collected from the same transmission arrangement that is being tested. Averages for the last 20 transmission arrangements should be maintained.

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Personal injury or death can result from escaping fluid under pressure.
Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause 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.

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Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

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Personal injury or death can result from not following the proper procedures.

To avoid the possibility of injury or death, follow the established procedure.

Tools Needed

Pressures will be sensitive to tooling setup. The diameter of the hose, the diameter of a fitting, and extra filtering can affect pressure. The required tools that are listed in Table 3 were used to develop this test procedure. These tools are suggested and may very depending on availability and bench configuration.

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Table 3
Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9585	Mounting Block Gp (Transmission)	1
	1U-9584	Rail As (Transmission Test Bench)	2
	245-6545	Support As	2
	8C-3413	Bolt (M12X1.75 mm)	8
	3B-4508	Lockwasher	8
	9U-5214	Support	2
	1D-4585	Bolt (3/8-11X3.25 inch)	8
	4K-0367	Full Nut	8
	5P-8247	Hard Washer	8
B	1U-5798	Drive Adapter Gp	1
	484-2106	Adapter	1
	0S-1585	Bolt (1/2-13X1.50 inch)	8
	5P-8245	Hard Washer	8
	8T-9515	Bolt (M10X1.50X40 mm)	6
C	1U-6698	Spindle Adapter	1
	4C-6174	Adapter Ring (Hub)	1
	0S-1588	Bolt (3/8-16X1.25 inch)	6
	5M-2894	Hard Washer	12
	2J-5245	Bolt (3/8-16X1.25 inch)	6
D	1U-5999	Spindle Gp	1
	0S-1587	Bolt (1/2-13X1.75 inch)	4
	3B-4508	Lockwasher	4
E	1U-6721	Adapter (Drive)	1
F	1U-9131	Drive Adapter (Key)⁽¹⁾	1
G	1U-9359	Drive Adapter⁽²⁾	1
H	439-3939	Link Bracket As	2
	9X-8881	Bolt (5/8-11X2.25 inch)	2
	5P-8247	Hard Washer	2
	1U-9722	Load Binder As (Ratchet Type)	2
X	245-6546	Plate Gp (Support)	1
	8T-0299	Bolt (M16X2.00X30 mm)	2
	9X-8268	Washer	2
J	1U-9853	Flange	1
	1P-3704	O-Ring Seal	1
	006-5707	Pipe Elbow	1
	6V-5218	Bolt (M8X1.25X25 mm)	2
	9M-1974	Hard Washer	2
	173-4410	Pipe Fitting	1
	2F-5277	Terminal Bushing	1
	5L-6669	Reducer Bushing	1
	1U-9879	Adapter	1
K	1U-9852	Flange	1
	1P-3704	O-Ring Seal	1
	6V-8675	Bolt (M12X1.75X35 mm)	2
	5P-8245	Hard Washer	2
	006-5707	Pipe Elbow	1
L	245-6547	Adapter (Suction)	1
L	122-9252	O-Ring Seal	1
M	061-9593	Reducer Bushing	1
M	3J-5389	Plug	1
N	002-6453	Elbow	1
	061-9593	Reducer Bushing	1
	002-6454	Pipe Nipple	1
	7X-7646	Fitting As	1
Y	061-9593	Reducer Bushing	1
	002-6454	Pipe Nipple	1
	7X-7646	Fitting As	1
P	8C-9024	Fitting As (Plain)	2
	7M-8485	O-Ring Seal	2
	5P-0492	Adapter	2
Q	8C-9024	Fitting As (Plain)	2
	8C-9025	Quick Coupler	2
	3B-7749	Fitting	2
	120-6843	Ball Valve	2
R	8T-0863	Pressure Gauge (0 to 250 kPa (0 to 36 psi))	1
R	6V-4144	Coupler	1
S	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	5
S	6V-4144	Coupler	5
T	164-1197	Rod As	1
U		DC Power Supply⁽³⁾	1
	155-2270	Connecting Plug Kit	1
	186-3736	Connector Socket	2
	5P-5677	Electrical Wire (18 AWG)	1
V	1U-6602	Photo-Tachometer	1
W	4C-4014	Relief Valve	1
	8C-9024	Fitting As (Plain)	1
	8C-9025	Quick Coupler	1
	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	1
	120-9181	Valve Body	1
	200-4103	Connector	1
	141-7280	Connector	1
	1L-4031	Connector	2
	061-9593	Connector	1

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⁽¹⁾	This drive adapter is used with the small drive shaft.
⁽²⁾	This drive adapter is used with the large drive shaft.
⁽³⁾	0 to 30 VDC and 0 to 10 amp.

Installation Procedure

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Illustration 3	g01034238
Typical Example

Install Tooling (A) on the transmission.
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Illustration 4 g01034239

Typical Example
Install Tooling (A) on the opposite side of the transmission.
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Illustration 5 g06003643
Install Tooling (A) on the transmission.
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Illustration 6 g01040744
Use a hoist to install the transmission on the test bench. The weight of the transmission is 227 kg (500 lb).
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Illustration 7 g01040746
Install Tooling (B) on the torque converter.
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Illustration 8 g01040747

Note: Remove the ring gear from Tooling (B).
Install Tooling (B).
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Illustration 9 g01040748
Install Tooling (C) to the transmission case.
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Illustration 10 g01040764

Note: Refer to Special Instruction, SEHS8763, "Assembly and Operation of 1U-5999 Spindle Group Used for Testing Transmissions on Hydraulic Test Bench" for additional information.
Install Tooling (D) on Tooling (C).
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Illustration 11 g01040768
Tighten the collet on Tooling (D) to connect Tooling (D) to Tooling (B).
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Illustration 12 g01040770
Install Tooling (E) to the input shaft of Tooling (D).
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Illustration 13 g01040771
Install Tooling (F) to the input shaft of Tooling (E).
Note: Tooling (F) will adapt to the small drive shaft. If you are using the large drive shaft, install Tooling (G) on Tooling (E).
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Illustration 14 g01040772
Align the transmission with the input drive shaft.
Connect the input drive shaft to Tooling (F).
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Illustration 15 g01034268
Install the drive shaft guard.
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Illustration 16 g03802221
Tighten all four castle nuts and jack bolts.
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Illustration 17 g01034270

Typical Example
Install Tooling (H) to Tooling (A).
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Illustration 18 g01034271

Typical Example
Install Tooling (H).
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Illustration 19 g01034275

Typical Example
Install pump drive (1).
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Illustration 20 g03125384

Typical Example
Install Tooling (X).
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Illustration 21 g01040794
Remove plate (2).
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Illustration 22 g01040797
Remove screen filter (3).
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Illustration 23 g01040802
Install Tooling (J).
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Illustration 24 g01040806
Remove drain plug (4).
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Illustration 25 g01040809
Install Tooling (K).
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Illustration 26 g01034304

Typical Example
Install Tooling (L).
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Illustration 27 g01040815
Install Tooling (M).
Install Tooling (N).
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Illustration 28 g03125437
Install Tooling (Y).
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Illustration 29 g01040819
Install Tooling (P).
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Illustration 30 g01040824
Install Tooling (Q).
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Illustration 31 g01040826
Install Tooling (P).
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Illustration 32 g01040829
Install Tooling (R).
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Illustration 33 g01040830
Install Tooling (S).
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Illustration 34 g01040835

Note: Perform this step only on applicable transmissions.
Install Tooling (S).
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Illustration 35 g01040838
Install Tooling (S).
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Illustration 36 g06006140
Install Tooling (T).
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Illustration 37 g01040841
Connect hose assembly (5) from the pump supply to Tooling (J).
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Illustration 38 g01040843
Connect hose assembly (6) from Tooling (N) to the No. 1 flow meter inlet.
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Illustration 39 g03125458
Connect hose assembly (7) from the No. 1 flow meter outlet to Tooling (Y).
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Illustration 40 g01040847

Torque Converter Outlet
Connect hose assembly (8) from Tooling (Q) to the No. 2 flow meter inlet.
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Illustration 41 g01040855

Inlet for the Transmission Lubrication Oil
Connect hose assembly (9) from the No. 2 flow meter outlet to Tooling (P).
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Illustration 42 g01040859

Lubrication for the Spindle
Connect lube line (10) from the test bench to Tooling (D). Maintain an oil pressure of 275 kPa (40 psi).
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Illustration 43 g01040864

Transmission Lubrication Pressure Tap

Note: If you are using individual pressure gauges to measure the pressures, refer to Table 3 for the correct pressure gauges.
Connect a pressure gauge to pressure tap (11).
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Illustration 44 g01040870

(12) Pump Pressure Tap
(13) Torque Converter Pressure Tap
Connect two pressure gauges to pressure taps (12) and (13).
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Illustration 45 g01040874

AWD Clutch Pressure Tap

Note: Perform this step only on applicable transmissions.
Connect a pressure gauge to pressure tap (14).
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Illustration 46 g01040877

(15) Forward Clutch Pressure Tap
(16) Reverse Clutch Pressure Tap
Connect two pressure gauges to pressure taps (15) and (16).
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Illustration 47 g01040891
Cover the transmission. Use a clean suitable cover.

Test Procedure

Start Checks

Note: Refer to Testing and Adjusting, RENR3575, "416D, 420D, 424D, 428D, 430D, 432D, 438D, and 442D Backhoe Loaders Transmission (Direct Drive)" for the correct adjusting procedures.

If you are using SAE 10W oil, warm the oil to 50 °C (125 °F). If you are using Mobil DTE11 oil, warm the oil to 34 °C (95 °F). Maintain this temperature for the duration of the test.
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Illustration 48 g02720621
With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1000 ± 25 rpm.
Shift the transmission through all gears to eliminate air from the transmission controls.
Stop the input rotation.

Torque Converter Relief Valve Check

With the transmission in the NEUTRAL position, adjust the input rotation to 1000 ± 25 rpm.
Use Tooling (Q) to momentarily block the flow at the converter outlet.
Open Tooling (Q).
Record the torque converter relief valve pressure in Table 6.
Verify the test point with the values in Table 5.

Low Idle Pressure Checks

With the transmission in the NEUTRAL position, adjust the input rotation to 1000 ± 25 rpm.
Record the pump flow, lube flow, pump pressure, and the lube pressure in Table 7.
Verify the test points with the values in Table 5.

High Idle Pressure Checks

With the transmission in the NEUTRAL position, adjust the input rotation to 1600 ± 25 rpm.
Record the pump flow, lube flow, pump pressure, and the lube pressure in Table 8.
Verify the test points with the values in Table 5.
With the input speed at 1600 ± 25 rpm, shift the transmission to the FORWARD. Record directional clutch pressure in Table 10.
Shift the transmission to the NEUTRAL position.
With the input speed at 1600 ± 25 rpm, shift the transmission to the REVERSE position. Record directional clutch pressure in Table 10.
Verify the test points with the values in Table 9.
Shift the transmission to the NEUTRAL position.

Transmission Gear Synchronization Check

Adjust input rotation to 1000 ± 25 rpm.
Engage the FORWARD clutch with the All Wheel Drive solenoid .
Engage FOURTH gear. Shift sequentially through the gears until NEUTRAL is reached.
From the NEUTRAL position, engage the REVERSE solenoid. Shift sequentially through the gears until FOURTH gear is reached.
Evaluate gear synchronization and transmission noise in each of the gears. Record findings in Table 11.
Shift the transmission to the NEUTRAL position.

All Wheel Drive System Check

Note: Perform this test only on applicable transmissions.

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Illustration 49	g01041225

Install Tooling (U).
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Illustration 50 g01034903

Tooling (U)

Note: Adjust Tooling (U) to 10 VDC and 2.5 amp, which is needed to actuate the all wheel drive solenoid.
Adjust input rotation to 1600 ± 25 rpm.
Shift the transmission to the NEUTRAL position.
To engage the all wheel drive solenoid, turn on Tooling (U).
Record the pressure of the All Wheel Drive clutch in Table 13.
Verify the test points with the values in Table 5.
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Illustration 51 g01041369

Typical Example
Tooling (V)

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Illustration 52 g01041370

Typical Example
Tooling (V)
Record the output speed of both front and rear drive shafts in each of the four FORWARD and four REVERSE gears in Table 14.
Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD to REVERSE.
Verify the test points with the values in Table 12.

Cold Start Valve Check

Note: Perform this test only on applicable transmissions.

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Illustration 53	g01041228

Install Tooling (W) on Tooling (N).
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Illustration 54 g01041229
Install Tooling (Q) on Tooling (W).
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Illustration 55 g01041230
Connect hose assembly (6) from Tooling (Q) to the No. 1 flow meter inlet.
Adjust input rotation to 1000 ± 25 rpm.
With the transmission in NEUTRAL, close Tooling (Q) and record pump pressure in Table 15.
Verify the test point with the value in Table 5.

Contamination Control

Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.
Record the results in Table 16.
Remove the transmission from the test bench if the test bench oil supply is within specifications.

Transmission Bench Test Data Sheet

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Table 4
CATERPILLAR	Transmission Bench Test Data Sheet	Test Date:_______
		Model:_______
Work Order:_______		Serial No.:_______

Specifications

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Table 5
Input Speed	1000 ± 25		1600 ± 25
Input Speed	Low	High	Low	High
Pump Flow	12 L/min (3 US gpm)	28 L/min (7 US gpm)	20 L/min (5 US gpm)	44 L/min (11 US gpm)
Lube Flow	4 L/min (1 US gpm)	24 L/min (6 US gpm)	12 L/min (3 US gpm)	44 L/min (11 US gpm)
Pump Pressure	1260 kPa (180 psi)	1600 kPa (230 psi)	1290 kPa (185 psi)	1680 kPa (240 psi)
Lube Pressure	27.6 kPa (4 psi)	2500 kPa (360 psi)	28 kPa (4 psi)	350 kPa (50 psi)
Torque Converter Relief Valve	830 kPa (119 psi)	1064 kPa (152 psi)
Cold Start Valve	2030 kPa (290 psi)	3550 kPa (508 psi)
All Wheel Drive Pressure			1290 kPa (185 psi)	1680 kPa (240 psi)

Torque Converter Relief Valve Check

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Table 6
Torque Converter Relief Valve Check	Input Speed (1000 ± 25 rpm)			_______kPa _______(psi)

Low Idle Pressure Checks

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Table 7
Low Idle Pressure Checks	Input Speed (1000 ± 25 rpm)
Low Idle Pressure Checks	Neutral
Pump Flow	_______kPa _______(psi)
Lube Flow	_______kPa _______(psi)
Pump Pressure	_______kPa _______(psi)
Lube Pressure	_______kPa _______(psi)

High Idle Pressure Checks

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Table 8
High Idle Pressure Checks	Input Speed (1600 ± 25 rpm)
High Idle Pressure Checks	Neutral
Pump Flow	_______kPa _______(psi)
Lube Flow	_______kPa _______(psi)
Pump Pressure	_______kPa _______(psi)
Lube Pressure	_______kPa _______(psi)

Directional Clutch Pressure Test

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Table 9
Directional Clutch Pressure Check	Input Speed (1600 ± 25 rpm)
Clutch	Low	High
FORWARD	1295 kPa (185 psi)	1295 kPa (185 psi)
REVERSE	1295 kPa (185 psi)	1295 kPa (185 psi)

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Table 10
Directional Clutch Pressure Check	Input Speed (1600 ± 25 rpm)	FORWARD	_______kPa _______(psi)
		REVERSE	_______kPa _______(psi)

Gear Synchronization Check

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Table 11
Gear Synchronization Check		Input Speed (1000 ± 25 rpm)
F4-F3	F3-F2	F2-F1	F1-N	N-R1	R1-R2	R2-R3	R3-R4
__________	__________	__________	_________	_________	_________	_________	________

All Wheel Drive System Check

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Table 12
All Wheel Drive System Check			Input Speed (1600 ± 25 rpm) NOTE: All figures below equal ± 25 rpm.
	N	F1	F2	F3	F4	R1	R2	R3	R4
Front Drive Shaft		272 rpm	397 rpm	484 rpm	879 rpm	272 rpm	397 rpm	484 rpm	879 rpm
Rear Drive Shaft		330 rpm	533 rpm	656 rpm	2020 rpm	330 rpm	533 rpm	656 rpm	2020 rpm

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Table 13
All Wheel Drive Pressure Check	Input Speed (1600 ± 25 rpm)			_______kPa _______(psi)

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Table 14
All Wheel Drive System Check			Input Speed (1600 ± 25 rpm) NOTE: All figures below equal ± 25 rpm.
	N	F1	F2	F3	F4	R1	R2	R3	R4
Front Drive Shaft		_______	_______	_______	_______	_______	_______	_______	_______
Rear Drive Shaft		_______	_______	_______	_______	_______	_______	_______	_______

Cold Start Valve Check

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Table 15
Cold Start Valve Check	Input Speed (1000 ± 25 rpm)			_______kPa _______(psi)

ISO Particle Count

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Table 16
ISO Particle Count	Sample the test bench oil supply. *ISO 4406 is 16/13 or better	________/________Particle Count

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Table 17
______________________________________ Technician	______________________________________ Supervisor

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Illustration 41	g01040855
Inlet for the Transmission Lubrication Oil




Illustration 43	g01040864
Transmission Lubrication Pressure Tap




Illustration 44	g01040870
(12) Pump Pressure Tap (13) Torque Converter Pressure Tap




Illustration 46	g01040877
(15) Forward Clutch Pressure Tap (16) Reverse Clutch Pressure Tap




Illustration 5	g06003643




Illustration 6	g01040744




Illustration 7	g01040746




Illustration 8	g01040747