Bench Test Procedure for a 918F, 924F Wheel Loader and IT18F, IT24F Integrated Toolcarrier Transmission {3030, 3073} Caterpillar

Integrated Toolcarrier

IT18F (S/N: 6ZF1-UP; 5EJ1-UP)

IT24F (S/N: 4NN1-UP; 6KN1-UP)

Wheel Loader

918F (S/N: 3TJ1-UP; 2CK1-UP)

924F (S/N: 4YN1-UP; 5NN1-UP; 6MN1-UP; 7PN1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS2303
04	Standardized.
03	Added new Introduction and Canceled Part Numbers section.

© 2015 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 questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. To address an urgent issue, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

• Cat Dealer Techinical Communicator

• Dealer Solution Network

• Cat Technical Representative

• Knowledge Network

Table 2

Machine Model	Transmission Arrangement
IT18F	6Y-2435, 108-2075, 102-7502
IT24F	6Y-2435, 108-2075, 102-7502
918F	6Y-2435, 108-2075, 102-7502
924F	6Y-2435, 108-2075, 102-7502

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

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.

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 used to compare values on portions of this transmission test. 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 to develop this test procedure.

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9584	Rail As	2
	4C-9998	Bracket As	2
	8T-0293	Bolts (M12 x 1.75-6H)	4
	5P-8245	Washer	8
	1U-6232	Crossmember As	1
	1D-4615	Bolts (3/4-10 x 5.5)	4
	2J-3506	Full Nut	4
	2S-0115	Hard Washer	8
B	1U-5798	Adapter As	1
C	4C-6174	Adapter (Hub)	1
	0S-1588	Bolt (3/8-16 x 1 1/4)	6
	1U-6698	Adapter As	1
	0S-1588	Bolts (3/8-16 x 1 1/4)	6
	8M-7145	Washer (3/8)	6
D	1U-5999	Spindle Group	1
	8B-7997	Bolts (1/2-13 x 2)	4
E	1U-6721	Drive Adapter	1
F	1U-9131	Drive Adapter(1)	1
G	1U-9359	Drive Adapter(2)	1
H	1U-9722	Ratcheting Turnbuckle	2
J	1U-6234	Adapter (Insert)	1
K	1U-6233	Oil Supply Adapter	1
	6V-5217	Bolts (M8 x 1.25-20mm)	3
	5P-3863	O-Ring	1
	3B-7286	Nipple	1
	7B-7138	Fitting	1
	3N-8699	Reducer	1
	1U-9879	Camlock Fitting	1
L	1U-8300	Fitting	1
	1U-9736	Fitting	1
	2S-4078	O-Ring	1
	7M-8485	O-Ring	1
	8C-9024	Nipple (Quick Disconnect)	1
M	5P-0492	Fitting	2
	7M-8485	O-Ring	2
	6B-3156	Nipple	1
	1U-8300	Fitting	1
	6V-3965	Nipple (Quick Disconnect)	1
	3J-1907	O-Ring	1
	8C-9024	Nipple (Quick Disconnect)	1
N	1U-8301	Fitting	1
	9U-7443	Adapter As	1
	1P-4576	Split Flange	2
	O5-8615	Nipple	1
	8C-9025	Coupler (Quick Disconnect)	1
	6V-1820	Bolts (M10 x 1.5-30mm)	4
	6V-3965	Nipple (Quick Disconnect)	1
	3J-1907	O-Ring	1
P	1U-8301	Fitting	1
	9U-7444	Adapter As	1
	1P-4577	Split Flange	2
	8C-9024	Nipple (Quick Disconnect)	1
	6V-1820	Bolts (M10 x 1.5-30mm)	4
R	4P-3117	Ball Valve or Gate Valve(3)	1
	8C-9024	Nipple (Quick Disconnect)	1
	8C-9025	Coupler (Quick Disconnect)	1
	3B-7749	Nipple (1.0 Shoulder)	1
S	9T-7038	Filter Group	1
	8C-9024	Nipple (Quick Disconnect)	2
T	8T-0855	Gauge	1
	6V-4144	Coupler (Quick Disconnect)	1
U	8T-0855	Gauge	1
	6V-4144	Coupler (Quick Disconnect)	1
V	8T-0855	Gauge	1
	6V-4144	Coupler (Quick Disconnect)	1
W	8T-0853	Gauge	1
	6V-4144	Coupler (Quick Disconnect)	1
X	8T-0854	Gauge	1
	6V-4144	Coupler (Quick Disconnect)	1
	6V-3965	Nipple (Quick Disconnect)	1
	3J-1907	O-Ring	1
Y	9U-7500	Transmission Analyzer Tool Gp	1
	OR
	277-2362	Transmission Analyzer Gp	1
	306-0397	Extension Cable	1
	459-4084	Adapter Cable Assembly	1

(1)	This drive adapter is used with the small drive shaft.
(2)	This drive adapter is used with the large drive shaft.
(3)	For reference Q, any ball valve or any gate valve can be used.

Installation Procedure

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Illustration 3	g01246285

1. Install Tooling (A) on the test bench.

2. Use a hoist to install the transmission on the test bench. The weight of the transmission is 432 kg (953 lb).
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   Illustration 4	g01246352
   Typical example

3. Install Tooling (B) on the torque converter.
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   Illustration 5	g01246349
   Typical example

4. Install Tooling (C) to the transfer case.
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   Illustration 6	g01246328

5. Install Tooling (D).
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   Illustration 7	g01247707
   Typical example

6. Tighten the collet on Tooling (D) 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 8	g01247713
   Typical example

7. Install Tooling (E).
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   Illustration 9	g01247714
   Typical example

8. Install Tooling (F).
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   Illustration 10	g01247720
   Typical example

9. Align the transmission with the input drive shaft.

10. Connect the input drive shaft to Tooling (F).
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    Illustration 11	g01247721
    Typical example

11. Install the drive shaft guard.
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    Illustration 12	g03802221

12. Tighten all four castle nuts and jack bolts.
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    Illustration 13	g01247732
    Typical example

13. Install Tooling (H) on the input end of the transmission.
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    Illustration 14	g01247733
    Typical example

14. Install Tooling (H) to the output end of the transmission.
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    Illustration 15	g01247764
    Typical example

15. Remove cover (1).
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    Illustration 16	g01247770
    Typical example

16. Remove magnetic filter (2).
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    Illustration 17	g01247778

17. Install Tooling (J).
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    Illustration 18	g01247791

18. Install Tooling (K).
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    Illustration 19	g01247951

19. Install Tooling (L).
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    Illustration 20	g01247982

20. Install Tooling (M).
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    Illustration 21	g01248004

21. Install Tooling (N).
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    Illustration 22	g01248014

22. Install Tooling (P).
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    Illustration 23	g01826898

23. Install Tooling (R) to Tooling (P).
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    Illustration 24	g01826913

24. Install Tooling (S) to Tooling (N).
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    Illustration 25	g01248135
    Oil Supply (3)

25. Connect hose assembly (3) from the test bench oil supply to Tooling (K).
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    Illustration 26	g01248166
    Pump Outlet (4)

26. Connect hose assembly (4) from Tooling (S) to the No. 1 flow meter inlet.
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    Illustration 27	g01248144
    Main Relief Valve and Clutch Supply Rail (5)

27. Connect hose assembly (5) from the No. 1 flow meter outlet to Tooling (L).
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    Illustration 28	g01248173
    Converter Outlet (6)

28. Connect hose assembly (6) from Tooling (R) to the No. 2 flow meter inlet.
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    Illustration 29	g01248159
    Lubrication Inlet (7)

29. Connect hose assembly (7) from the No. 2 flow meter outlet to Tooling (M).
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    Illustration 30	g01826933
    Speed Clutch Pressure "P1"

30. Install Tooling (T).
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    Illustration 31	g01826953
    Directional Clutch Pressure "P2"

31. Install Tooling (U).
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    Illustration 32	g01826973
    Torque Converter Inlet Pressure "P3"

32. Install Tooling (V).
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    Illustration 33	g01826974
    Lubrication Pressure

33. Install Tooling (W).
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    Illustration 34	g01826994
    Torque Converter Outlet Pressure

34. Install Tooling (X).
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    Illustration 35	g01826998

35. Connect Tooling (Y) to the transmission.
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    Illustration 36	g01248384
    Tooling (Y)

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    Illustration 37	g01457869
    Tooling (Y)

36. Connect Tooling (Y) to a power source. Refer to Tool Operating Manual, NEHS0644 or Tool Operating Manual, NEHS0996 for the correct operating instructions.

    Note: Make sure that the transmission is secured to the test bench. Tighten all bolts to the proper torque.

Test Procedure

TA3 Navigation

1. Select "Wheel Loaders" or "Tool Carriers".

2. Select “IT18F-24V”, “IT24F-24V”, “918F-24V”, or “924F-24V”.

Harness Test (TA3 only)

1. Make sure that the harness is properly connected.

2. Use Tooling (Y) to perform the harness test.

3. Record the values in Table 6.

   Note: Do not continue testing until Harness Test passes.

Solenoid Test (TA2 only)

1. Make sure that the harness is properly connected.

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

3. Record the values in Table 6.

   Note: Do not continue testing until Solenoid Test passes.

Start Checks

Note: Refer to Testing and Adjusting, SENR5904, "IT18F Integrated Toolcarrier Power Train" 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 Mobil DTE11 oil, warm the oil to 34 °C (95 °F). Maintain this temperature for the duration of the test.

2. Adjust the input flow to 28 ± 4 L/min (7 ± 1 US gpm).
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   Illustration 38	g02720621

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 850 ± 25 rpm.

4. Shift the transmission through all gears to eliminate air from the transmission controls.

5. The lubrication pressure must be between 14 kPa (2 psi) and 28 kPa (4 psi).

   Note: If there is no lube pressure after 3 seconds, stop input rotation and check connections on test bench and transmission.

6. Record the value in Table 8.

7. Confirm the correct clutch engagement with Table 4.
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   Table 4

   Clutch Engagement Check
   Gear	Cl 1	Cl 2	Cl 3	Cl 4	Cl 5	Cl 5
   F1			X	X
   F2			X		X
   F3			X			X
   F4	X					X
   R1		X		X
   R2		X			X
   R3		X				X

Check of the Torque Converter Inlet Ratio Valve

1. Adjust the input flow to 28 ± 4 L/min (7 ± 1 US gpm). Maintain this flow during this check.

2. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 850 ± 25 rpm.

3. Shift the transmission to FORWARD 1.

4. Momentarily block the lube flow.

5. The torque converter inlet pressure must be 1000 ± 138 kPa (145 ± 20 psi).

6. Open the lube flow.

7. Record the value in Table 10.

Lube Circuit Check

1. Adjust the input flow until the lube flow is 84 ± 4 L/min (22 ± 1 US gpm). Maintain this flow during this check.

2. Adjust the input rotation to 850 ± 25 rpm.

3. Shift the transmission to the FORWARD 2 position.

4. The lubrication pressure must be within ±10 kPa (±2 psi) of the test bench average for this arrangement. Reference is 158 kPa (23 psi).

5. Record the value in Table 11.

Clutch Leakage Check

1. Adjust the input flow to 84 ± 4 L/min (22 ± 1 US gpm). Maintain this flow during this check.

2. Adjust the input rotation to 850 ± 25 rpm.

3. Shift the transmission to the FORWARD 1 position.

4. Adjust the input rotation to 2400 ± 25 rpm.

5. Record the input flow in Table 12.

6. Record the lube flow in Table 12.

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

8. Record the calculation in Table 12.

9. Adjust the input rotation to 850 ± 25 rpm.

10. Shift the transmission through positions FORWARD 2, FORWARD 3, REVERSE 1, REVERSE 2, REVERSE 3, and NEUTRAL. Repeat Steps 4 through 9 for each gear range.

    Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.

11. The leakage difference between SECOND and THIRD gears or between FORWARD and REVERSE should not exceed 17 L/min (4.5 US gpm).

12. The difference in lubrication flow between the FIRST, SECOND, and THIRD gear ranges must not exceed 3 L/min (0.8 US gpm) of the test bench average for this arrangement. Reference is 6.4 ± 3 L/min (1.7 ± 0.8 US gpm).

13. Record the calculations in Table 12.

14. Stop the input rotation.

15. Stop the input flow.

Transmission Bench Test Data Sheet

Table 5

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

Solenoid Test

Table 6

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

Specifications

Table 7

Specifications
Description	High Idle	Low Idle
Input Speed	2400 ± 25 rpm	850 ± 25 rpm
Input Flow	84 ± 4 L/min (22 ± 1 US gpm)	28 ± 4 L/min (7 ± 1 US gpm)
Minimum Lube Flow	68 L/min (18 US gpm)	-
Pressures
Torque Converter Outlet Pressure	-	240 ± 35 kPa (35 ± 5 psi)
"P1" Pressure	P2 + 276 ± 70 kPa P2 + 40 ± 10 psi	P2 + 200 ± 70 kPa P2 + 29 ± 10 psi
"P2" Pressure	2137 ± 140 kPa (310 ± 20 psi)	2137 ± 140 kPa (310 ± 20 psi)
"P3"Pressure	-	1000 ± 140 kPa (145 ± 20 psi)
Lubrication Pressure	157 ± 28 kPa (23 ± 4 psi)	-

Start Checks

Table 8

Lubrication Pressure	Input Speed (850 ± 25 rpm)	_______kPa _______(psi)
	Input Flow 28 ± 4 L/min (7 ± 1 US gpm)

Initial Pressure Check

Table 9

Initial Pressure	Input Speed (850 ± 25 rpm)	_______kPa _______(psi)
	Input Flow 28 ± 4 L/min (7 ± 1 US gpm)

Check of the Torque Converter Inlet Ratio Valve

Table 10

Pressure for the Torque Converter Inlet Ratio Valve	Input Speed (850 ± 25 rpm)	_______kPa _______(psi)
	Input Flow 28 ± 4 L/min (7 ± 1 US gpm)

Lube Circuit Check

Table 11

Lube Circuit Check		Gear Range FORWARD 2
		Input Speed (850 ± 25 rpm)
		Lube Flow 84 ± 4 L/min (22 ± 1 US gpm)
Average Lubrication Pressure Of Arrangement	_______kPa _______(psi)	Lubrication Pressure	_______kPa _______(psi)

Clutch Leakage Check

Table 12

Clutch Leakage Check			Input Speed (2400 ± 25 rpm)
			Input Flow 84 ± 4 L/min (22 ± 1 US gpm)
Gear Range	N	F1	F2	F3	R1	R2	R3
Input Flow	______	______	______	______	______	______	______
Lube Flow	______	______	______	______	______	______	______
Leakage	______	______	______	______	______	______	______

Contamination Control

Table 13

ISO Particle Count

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

________/________Particle Count

Table 14

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