Bench Test Procedure for a 924G, 924GZ, 924H, 924HZ, 928G, 928H, 928HZ, 930G, 930H Wheel Loader and IT28G Integrated Toolcarrier Transmission{3030, 3073, 3139} Caterpillar

Integrated Toolcarrier:

IT28G (S/N: WAC1-UP; EWF1-UP; DBT1-UP)

Wheel Loader:

924G (S/N: DDA1-UP; EEB1-UP; RBB1-UP; WMB1-UP)

924GZ (S/N: RTA1-UP; WGX1-UP; DFZ1-UP)

924H (S/N: HXC1-UP; JTM1-UP; KLN1-UP; RRS1-UP; LKW1-UP)

924HZ (S/N: WLB1-UP; PED1-UP; JRL1-UP; JZZ1-UP)

928G (S/N: DJD1-UP; WLG1-UP)

928H (S/N: RSB1-UP)

928HZ (S/N: BYD1-UP; CXK1-UP)

930G (S/N: TWR1-UP; TFW1-UP)

930H (S/N: DHC1-UP; FTD1-UP)

Introduction

Table 1

Summary of Changes in REHS2139
05	Added serial number prefixes and transmission arrangements.
04	Added transmission arrangement 290-1257 and serial number prefixes RRS and JRL
03	Added additional serial number prefix and transmission arrangements.

© 2013 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.

This special instruction contains the necessary information that is required to bench test a specific transmission arrangement. 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. Testing 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 in order 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 questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. In order to address an urgent issue, use the following resources in order to communicate your request to Caterpillar Repair Process Engineering:

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Table 2

Machine Model	Transmission Arrangement
924G	180-7500, 180-7503
924GZ	180-7500, 180-7503
924H	290-1257, 290-7159
924HZ	290-1257, 290-7159
928G	177-0017
928H	290-2719
928HZ	290-2719, 290-2720
930G	234-8866
930H	290-2719, 290-2720
IT28G	177-0017

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.

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 in order 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.

Required Tools

Note: Pressures will be sensitive to tooling setup. The diameter of the hose, the diameter of a fitting, and additional filtering can affect pressure. The required tools that are listed in Table 3 were used in order to develop this test procedure.

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9585	Block Gp (TRANSMISSION)	1
	1U-9584	Rail As	2
	1U-9586	Swivel Head Support Gp	1
	FT0703	Support Assembly	1
B	1U-5798	Drive Adapter Gp	1
	236-4489	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
	1A-1460	Bolt (1/2-13X2.00 inch)	4
	3B-4508	Lockwasher	4
E	1U-6721	Adapter As (DRIVE)	1
F	1U-9131	Drive Adapter (KEY) (1)	1
G	1U-9359	Drive Adapter (2)	1
H	138-7573	Link Bracket	2
	6V-8197	Bolt (M12X1.75X40 mm)	2
	6V-5839	Washer	2
	3B-4508	Lockwasher	2
	1U-9722	Load Binder As (RATCHET TYPE)	3
J	1U-6234	Adapter (Oil Supply)	1
	4F-7390	O-Ring Seal	1
K	1U-6233	Adapter	1
	6V-3940	Bolt (M8X1.25X25 mm)	3
	9M-1974	Hard Washer	3
	5N-2918	Fitting	1
	5L-6669	Reducer Bushing	1
	1U-9879	Adapter	1
L	1U-9871	Flange	1
	4J-5267	O-Ring Seal	1
	8T-0271	Bolt (M10X1.5X35 mm)	4
	004-7270	Pipe Fitting	1
	6B-9081	Reducing Bushing	1
	7X-7646	Fitting As	1
M	8C-9024	Fitting As (PLAIN)	1
	5P-0492	Adapter	1
	7M-8485	O-Ring Seal	1
	7X-2470	Adapter	1
	2S-4078	O-Ring Seal	1
N	8C-9024	Fitting As (PLAIN)	1
	5P-0492	Adapter	1
	7M-8485	O-Ring Seal	1
P	8C-9024	Fitting As (Plain)	1
	8C-9025	Quick Coupler	1
	3B-7749	Fitting	1
	120-6843	Ball Valve	1
R	8C-9024	Fitting As (Plain)	1
	5P-0492	Adapter	1
	7M-8485	O-Ring Seal	1
S	9U-7500	Electronic Control Group	1
	9U-7498	Extension Cable	1
	9U-7497	Adapter Cable As	1
T	146-4080	Digital Multimeter	1
	186-3736	Connector Socket	2
	5P-5677	Electrical Wire	1
	155-2270	Connecting Plug Kit	1
		Plug Assembly (Double Banana) (3)	1
U	8T-0862	Pressure Gauge (−100 to 500 kPa (−15 to 72 psi))	1
	6V-4144	Coupler	1
V	8T-0855	Pressure Gauge (0 TO 4,000 kPa (0 TO 580 PSI))	3
	6V-4144	Coupler	3

( 1 )	This drive adapter is used with the small drive shaft.
( 2 )	This drive adapter is used with the large drive shaft.
( 3 )	Pomona Model 1330-0

Installation Procedure

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Illustration 1	g00988581

1. Install Tooling (A) on the test bench, as shown.

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Illustration 2	g00988582

2. Use a hoist to install the transmission on the test bench. The weight of the transmission is approximately 499 kg (1100 lb).

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Illustration 3	g00992752

3. Remove flex plate (1) .

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Illustration 4	g00992753

Note: Remove the ring gear from Tooling (B) .

4. Install Tooling (B) on the torque converter, as shown.

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Illustration 5	g00992755

5. Install Tooling (B) .

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Illustration 6	g00992759

6. Install Tooling (C) to the transmission case.

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Illustration 7	g00988587

7. Install Tooling (D) on Tooling (C) .

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Illustration 8	g00988590

8. Tighten the collet on Tooling (D) in order to connect Tooling (D) to Tooling (B) .

   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.

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Illustration 9	g00988591

9. Install Tooling (E) to the input shaft of Tooling (D) .

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Illustration 10	g00988595

10. 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 (F) .

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Illustration 11	g00988596

11. Align the transmission with the input drive shaft. Connect the input drive shaft to Tooling (F) .

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Illustration 12	g01207224

12. Install the drive shaft guard.

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Illustration 13	g01061287

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Illustration 14	g01061289

13. Install Tooling (H) to the output end of the transmission.

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Illustration 15	g01061373

14. Install Tooling (H) to the input end of the transmission.

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Illustration 16	g00992761

15. Remove drain plug (2) .

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Illustration 17	g01061439

16. Remove cover (3) .

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Illustration 18	g00992765

17. Remove magnetic filter (4) .

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Illustration 19	g01847476

18. Install Tooling (J). Orient the slot in an upward position, as shown.

    Note: Tooling (J) will divert oil to the suction side of the transmission pump. Also, Tooling (J) will prevent oil from filling the oil pan.

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Illustration 20	g01847482

19. Install Tooling (K) .

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Illustration 21	g01847483

20. Install Tooling (L) .

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Illustration 22	g01847484

21. Install Tooling (M) .

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Illustration 23	g01847493

22. Install Tooling (N) .

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Illustration 24	g01847513

23. Connect Tooling (P) to Tooling (N) .

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Illustration 25	g01847594

24. Install Tooling (R) .

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Illustration 26	g01207230

25. Connect hose assembly (5) from the pump supply to Tooling (K) .

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Illustration 27	g01207231
Pump flow (6)

26. Connect hose assembly (6) from the No. 1 flow meter inlet to Tooling (M) .

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Illustration 28	g01207232
Supply flow (7)

27. Connect hose assembly (7) from the outlet of the No. 1 flow meter to Tooling (N) .

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Illustration 29	g01207233
Torque converter outlet (8)

28. Connect hose assembly (8) from the No. 2 flow meter inlet to Tooling (P) .

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Illustration 30	g01207234
Transmission lubrication oil (9)

29. Connect hose assembly (9) from the outlet of the No. 2 flow meter to Tooling (O) .

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Illustration 31	g01207235
Lubrication for the spindle bearing (10)

30. 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 32	g01061466
Pump pressure (11)

31. Connect a pressure gauge to pressure tap (11) in order to check the pump pressure.

    Note: If you are using individual pressure gauges to measure the pressures, refer to Table 3 for the correct pressure gauges.

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Illustration 33	g01061477
Torque converter inlet pressure (12)

32. Connect a pressure gauge to pressure tap (12) in order to check the torque converter inlet pressure.

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Illustration 34	g01061484
Torque converter outlet pressure (13)

33. Connect a pressure gauge to pressure tap (13) .

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Illustration 35	g01061491
Transmission lubrication pressure (14)

34. Connect a pressure gauge to pressure tap (14) .

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Illustration 36	g01061492
(15) Cable connector "(2-B)" for No. 2 "FORWARD HIGH" solenoid (16) Cable connector "(1-A)" for No. 1 "FORWARD LOW" solenoid (17) Cable connector "(3-C)" for No. 3 "REVERSE" solenoid (18) Cable connector "(4-D)" for No. 4 "SECOND SPEED"solenoid (19) Cable connector "(5-E)" for No. 5 "THIRD SPEED" solenoid (20) Cable connector "(6-F)" for No. 6 "FIRST SPEED" solenoid

35. Connect Tooling (P) to six clutch solenoids, as shown.

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Illustration 37	g01847599

36. Connect Tooling (S) to a suitable location, as shown.

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Illustration 38	g00877510
Tooling (S)

37. Connect Tooling (S) to a power source. Refer to Tool Operating Manual, NEHS0644 for the correct operating instructions.

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Illustration 39	g00988665

38. Cover the transmission. Use a clean suitable cover.

Test Procedure

Solenoid Test

1. Make sure that the harness is properly connected.

2. Use Tooling (S) to perform the solenoid test.

3. Record the values in Table 7.

Start Checks

Note: Refer to Testing and Adjusting, KENR7605, "924H, 924HZ, 928HZ, and 930H Wheel Loaders", Testing and Adjusting, RENR8725, "930G Wheel Loader", or Testing and Adjusting, RENR6425-03, "IT28G Integrated Toolcarrier and 924G, 924GZ, and 928G Wheel Loaders" for the correct adjusting procedures.

1. If you are using SAE 10W oil, warm the oil to 50 °C (125 °F). If you are using MobilDTE11 oil, warm the oil to 34 °C (95 °F). Maintain this temperature for the duration of the test.

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Illustration 40	g02720621

2. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 850 ± 25 rpm. Input flow should be 29 ± 3 L/min (7.7 ± 0.8 US gpm).

3. Shift the transmission through all speed ranges in order to eliminate air from the transmission controls.

4. Stop the input rotation.

Torque Converter Inlet Relief Valve

1. With the transmission in the NEUTRAL position, adjust the input rotation to 850 ± 25 rpm.

2. Shift the transmission to FORWARD 1.

3. Use Tooling (P) in order to block the flow momentarily at the torque converter outlet.

4. The torque converter inlet pressure must be 1000 ± 100 kPa (145 ± 14.5 psi).

5. Open Tooling (P) .

6. Record the value in Table 8.

7. Shift the transmission to the NEUTRAL position.

Low Idle Pressure Checks

1. With the transmission in the NEUTRAL position, adjust the input rotation to 850 ± 25 rpm.

2. Record input flow, lube flow, leakage, relief pressure, pump pressure, lubrication pressure, torque converter inlet pressure, and torque converter outlet pressure in Table 9.

   Note: The leakage is obtained by subtracting the lube flow from the input flow.

3. Compare the values with the values in Table 5.

4. Shift the transmission through each FORWARD and REVERSE speed ranges. Repeat Steps 2 and 3 for each position.

   Note: Do not shift the transmission in an opposite direction when the transmission output yoke is still in motion.

5. Shift the transmission to the NEUTRAL position.

6. Stop the input rotation.

High Idle Pressure Checks

1. With the transmission in the NEUTRAL position, adjust the input rotation to 2300 ± 25 rpm.

2. Record input flow, lube flow, leakage, relief pressure, pump pressure, lubrication pressure, torque converter inlet pressure, and torque converter outlet pressure in Table 10.

   Note: The leakage is obtained by subtracting the lube flow from the input flow.

3. Compare the values with the values in Table 5.

4. Shift the transmission through each FORWARD and REVERSE speed range. Repeat Steps 2 and 3 for each position.

   Note: Do not shift the transmission in an opposite direction when the transmission output yoke is still in motion.

5. Shift the transmission to the NEUTRAL position.

6. Stop the input rotation.

Speed Sensor Test

Note: Transmission arrangements will have five speed sensors that must be tested. There is one input speed sensor, two intermediate speed sensors, and two output speed sensors. Take care to identify each speed sensor.

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Illustration 41	g01847602
Typical Example

1. Connect Tooling (T) to speed sensors .

2. Adjust the input rotation to 910 ± 10 rpm.

3. Shift the transmission to FORWARD 2.

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Illustration 42	g01061562
(21) Input speed sensor (22) Intermediate speed sensor "No. 1" (23) Intermediate speed sensor "No. 2" (24) Output speed sensor "No. 1" (25) Output speed sensor "No. 2"

4. Use Tooling (T) to measure the sensor signal voltage. Measure each speed sensor.

5. Record the values in Table 11.

6. Verify the test points with the values in Table 4.
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   Table 4

   Sensor	Minimum Voltage
   	Volts (peak to peak)	Volts (VRMS)
   Input	10	3.53
   Output Speed Sensor 1	3.5	1.23
   Output Speed Sensor 2	3.5	1.23
   Intermediate Speed Sensor 1	5	1.76
   Intermediate Speed Sensor 2	5	1.76

Contamination Control

1. Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.

2. Record the results in Table 12.

3. Remove the transmission from the test bench if the test bench oil supply is within specifications.

Specifications

Table 5

Specifications
Description	High Idle	Low Idle
Input Speed	2300 ± 25 rpm	850 ± 25 rpm
Input Flow	88 ± 4 L/min (23.2 ± 1 US gpm)	29 ± 3 L/min (7.7 ± 0.8 US gpm)
Maximum Clutch Leakage	11.4 L/min (3.0 US gpm)
Pressures
Pump Pressure	2275.3 kPa (350 minimum psi)	2137.4 kPa (310 psi)
Relief Pressure	2400 ± 50 kPa (348 ± 7.3 psi)	2100 kPa (304.5 psi) Minimum
Torque Converter Inlet Relief Valve (1)	-	1000 ± 100 kPa (145.0 ± 14.5 psi)
Lubrication Pressure	210 ± 50 kPa (30.5 ± 7.3 psi)	20 kPa (2.9 psi) Minimum
Torque Converter Inlet Pressure	580 ± 70 kPa (84.1 ± 10.2 psi)	275 ± 75 kPa (39.9 ± 10.9 psi)
Torque Converter Outlet Pressure	350 ± 45 kPa (50.8 ± 6.5 psi)	250 ± 50 kPa (36.3 ± 7.3 psi)

( 1 )

The transmission input speed is set at 850 ± 50 rpm in FWD.

Transmission Bench Test Data Sheet

Table 6

CATERPILLAR	Transmission Bench Test Data Sheet	Test Date
		Model
Work Order		Serial No.

Solenoid Test

Table 7

Solenoid Test	Solenoid 1	Solenoid 2	Solenoid 3	Solenoid 4	Solenoid 5	Solenoid 6
	_______ ohms	_______ ohms	_______ ohms	_______ ohms	_______ ohms	_______ ohms

Torque Converter Inlet Relief Valve Check

Table 8

Relief Valve Check (Torque Converter Inlet) (1)

Input Speed (850 ± 25 rpm)

kPa(psi)

( 1 )

The transmission input speed is set at 850 ± 50 rpm in 1 FWD.

Low Idle Pressure Checks

Table 9

Low Idle Pressure Checks			Input Speed (850 ± 25 rpm)
Gear Range	N	1F	2F	3F	4F	1R	2R	3R
Input Flow
Lubrication Flow
Clutch Leakage (1)
Relief Pressure
Pump Pressure
Torque Converter Inlet Pressure
Torque Converter Outlet Pressure
Lubrication Oil Pressure

( 1 )

Clutch Leakage is calculated by subtracting the Lubrication Flow from the Input Flow.

High Idle Pressure Checks

Table 10

High Idle Pressure Checks			Input Speed (2300 ± 25 rpm)
Gear Range	N	1F	2F	3F	4F	1R	2R	3R
Input Flow
Lubrication Flow
Clutch Leakage (1)
Relief Pressure
Pump Pressure
Torque Converter Inlet Pressure
Torque Converter Outlet Pressure
Lubrication Oil Pressure

( 1 )

Clutch Leakage is calculated by subtracting the Lubrication Flow from the Input Flow.

Speed Sensor Test

Table 11

Speed Sensor Test	Input Speed (910 ± 10 rpm)
	Gear Range FORWARD 2
Input Speed Sensor	__________________ Volts/VRMS
Output Speed Sensor 1	__________________ Volts/VRMS
Output Speed Sensor 2	__________________ Volts/VRMS
Intermediate Speed Sensor 1	__________________ Volts/VRMS
Intermediate Speed Sensor 2	__________________ Volts/VRMS

Contamination Control

Table 12

Particle Count

Sample the test bench oil supply. ISO 4406 is 16/13.

________/________Particle Count

Table 13

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