Bench Test Procedure for a 928F Wheel Loader and IT28F Integrated Toolcarrier Transmission {3030, 3073} Caterpillar

Integrated Toolcarrier

IT28F (S/N: 1JL1-UP; 3CL1-UP)

Wheel Loader

928F (S/N: 8AK1-UP; 2XL1-UP; 7YM1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS2304
02	Standardized.
01	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 need, 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
928F	6Y-8243, 6Y-8244
IT28F	6Y-8243, 6Y-8244

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 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.

Show/hide table

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.

Show/hide table

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Show/hide table

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

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9584	Rail As	2
	4C-9998	Bracket Assembly	2
	8T-0281	Bolt (M16 x 2-80 mm)	4
	5P-8247	Washer	4
	1U-9035	Bracket Assembly	1
	1D-4615	Bolt (3/4-10 x 5.5)	4
	2J-3506	Nut (3/4)	4
	2S-0115	Hard Washer	4
B	1U-5798	Adapter Assembly	1
C	1U-6698	Adapter Assembly	1
	0S-1588	Bolt (3/8-16 x 1 1/4)	6
	8M-7145	Washer (3/8)	6
D	1U-5999	Spindle Group	1
	8B-7997	Bolt (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-9037	Adapter	1
K	1U-9036	Oil Supply Adapter	1
	8H-7521	O-Ring	1
	3B-7286	Nipple (Pipe)	1
	7B-7138	Elbow	1
	3N-8699	Reducer	1
	1U-9879	Nipple	1
	6V-1820	Bolt (M8 x 1.25-20mm)	3
L	1U-8301	Elbow	1
	9U-7444	Adapter As	1
	1P-4577	Split Flange	2
	005-8615	Nipple (Pipe)	1
	8C-9025	Coupler (Quick Disconnect)	1
	6V-1820	Bolt (M10 x 1.5-30mm)	4
	6V-3965	Nipple (Quick Disconnect)	1
	3J-1907	O-Ring	1
M	1U-8304	Port	1
	9U-7444	Adapter As	1
	1P-4577	Split Flange	2
	6V-1820	Bolt (M10-1.5 x 30mm)	4
	6V-3965	Nipple (Quick Disconnect)	1
	3J-1907	O-Ring	1
	8C-9024	Nipple (Quick Disconnect)	1
N	1U-8304	Port	1
	9U-7444	Adapter As	1
	1P-4577	Split Flange	2
	6V-1820	Bolt (M10-1.5 x 30mm)	4
	6V-3965	Nipple (Quick Disconnect)	1
	3J-1907	O-Ring	1
	8C-9024	Nipple (Quick Disconnect)	1
P	1U-8301	Elbow	1
	9U-7444	Adapter As	1
	1P-4577	Split Flange	2
	8C-9024	Nipple (Quick Disconnect)	1
	6V-1820	Bolt (M10 x 1.5-30mm)	4
	4P-3117	Ball Valve	1
	8C-9024	Nipple (Quick Disconnect)	1
	8C-9025	Coupler (Quick Disconnect)	1
	3B-7749	Nipple (Close)	1
R	9T-7038	Filter Group	1
	8C-9024	Nipple (Quick Disconnect)	2
S	8T-0853	Gauge	1
	6V-4144	Coupler (Quick Disconnect)	1
T	8T-0855	Gauge	1
	6V-4144	Coupler (Quick Disconnect)	1
U	9U-7500	Transmission Analyzer Tool Gp	1
	OR
	277-2362	Transmission Analyzer III Gp	1
	306-0397	Extension Cable	1
	1U-9480	Cable Adapter
	241-4879	Cable Adapter
	9U-7497	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.

Installation Procedure

Show/hide table

Illustration 3	g06016574

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 701 kg (1545 lb).
   Show/hide table

   Illustration 4	g01250441
   Typical example

3. Install Tooling (B) on the torque converter.
   Show/hide table

   Illustration 5	g01250443
   Typical example

4. Install Tooling (C) to the transfer case.
   Show/hide table

   Illustration 6	g01250447

5. Install Tooling (D).
   Show/hide table

   Illustration 7	g01250492

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.

   Show/hide table

   Illustration 8	g01250495
   Typical example

7. Install Tooling (E).
   Show/hide table

   Illustration 9	g01250496
   Typical example

8. Install Tooling (F).

   Note: Tooling (E) will adapt to the small drive shaft. If you are using the large drive shaft, install Tooling (G) on Tooling (E).

   Show/hide table

   Illustration 10	g01250509

9. Align the transmission with the input drive shaft.

10. Connect the input drive shaft to Tooling (F).
    Show/hide table

    Illustration 11	g01250511

11. Install the drive shaft guard.
    Show/hide table

    Illustration 12	g03802221

12. Tighten all four castle nuts and jack bolts.
    Show/hide table

    Illustration 13	g01250512
    Typical example

13. Install Tooling (H) on the input end of the transmission.
    Show/hide table

    Illustration 14	g01250513
    Typical example

14. Install Tooling (H) on the output end of the transmission.
    Show/hide table

    Illustration 15	g01250665
    Typical example

15. Remove cover (1).
    Show/hide table

    Illustration 16	g01250669
    Typical example

16. Remove cover (2) .
    Show/hide table

    Illustration 17	g01250527
    Typical example

17. Remove Cover (3).
    Show/hide table

    Illustration 18	g01250528
    Typical example

18. Remove magnetic filter (4).
    Show/hide table

    Illustration 19	g01250553
    Typical example

19. Install Tooling (J).
    Show/hide table

    Illustration 20	g01250559

20. Install Tooling (K).
    Show/hide table

    Illustration 21	g01250693

21. Install Tooling (L).
    Show/hide table

    Illustration 22	g01250699

22. Install Tooling (M).
    Show/hide table

    Illustration 23	g01250705

23. Install Tooling (N).
    Show/hide table

    Illustration 24	g01250719

24. Install Tooling (P).
    Show/hide table

    Illustration 25	g01250952

25. Install Tooling (R) to Tooling (L).
    Show/hide table

    Illustration 26	g01250726
    Oil Supply (5)

26. Connect hose assembly (5) from test bench oil supply to Tooling (K).
    Show/hide table

    Illustration 27	g01250955
    Typical example Pump Outlet (6)

27. Connect hose assembly (6) from Tooling (R) to the No. 1 flow meter inlet.
    Show/hide table

    Illustration 28	g01250971
    Main Relief Valve and Clutch Supply Rail (7)

28. Connect hose assembly (7) from the No. 1 flow meter outlet Tooling (N).
    Show/hide table

    Illustration 29	g01250992
    Torque Converter Outlet (8)

29. Connect hose assembly (8) from Tooling (P) to the No. 2 flow meter inlet.
    Show/hide table

    Illustration 30	g01250980
    Lubrication Inlet (9)

30. Connect hose assembly (9) from the No. 2 flow meter outlet to Tooling (M).
    Show/hide table

    Illustration 31	g01251006
    Lubrication Pressure (S)

31. Install Tooling (S).
    Show/hide table

    Illustration 32	g01251009
    Speed Clutch Pressure "P1" (T)

32. Install Tooling (T).
    Show/hide table

    Illustration 33	g01251021
    Direction Clutch Pressure "P2"

33. Install Tooling (T).
    Show/hide table

    Illustration 34	g01251023
    Torque Converter Inlet Pressure "P3"

34. Install Tooling (T).
    Show/hide table

    Illustration 35	g01251060
    Typical example

35. Connect Tooling (U) in a suitable location.
    Show/hide table

    Illustration 36	g00877510

    Show/hide table

    Illustration 37	g01457869
    Tooling (U)

36. Connect Tooling (U) 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 “928F-24V” or “IT28F-24V”.

Harness Test (TA3 only)

1. Make sure that the harness is properly connected.

2. Use Tooling (U) 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 (U) 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, SENR5994, "928F Wheel Loader 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.
   Show/hide table

   Illustration 38	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 47 ± 4 L/min (12 ± 1 US gpm).

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

4. Confirm the correct clutch engagement with Table 4.
   Show/hide table

   Table 4

   Clutch Engagement Check
   Gear	Cl 1	Cl 2	Cl 3	Cl 4	Cl 5	Cl 6
   F1			X	X
   F2			X		X
   F3			X			X
   F4	X					X
   R1		X		X
   R2		X			X
   R3		X				X

5. Stop the input rotation.

Check of the 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) to momentarily block the flow at the torque converter outlet.

4. The "P3" torque converter inlet pressure must be 1020 ± 140 kPa (148 ± 20 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 the input flow, the "P1" pressure, and the "P2" pressure in Table 9.

3. Verify the test points with the values in Table 7.

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

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

High Idle Pressure Checks

1. With the transmission in the NEUTRAL position, adjust the input rotation to 2200± 25 rpm.

2. Record the input flow, the oil cooler flow, the "P1" pressure, the "P2" pressure, and lubrication pressure in Table 10.

3. Verify the test points with the values in Table 7.

4. Shift the transmission to low idle.

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

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

6. Shift the transmission to the NEUTRAL position.

7. Stop the input rotation.

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 11.

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

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	Solenoid 6
	_______ ohms	_______ ohms	_______ ohms	_______ ohms	_______ ohms	_______ ohms

Specifications

Table 7

General Specifications
Description	High Idle	Low Idle
Input Speed	2200 ± 25 rpm	850 ± 25 rpm
Input Flow	127 ± 5 L/min (34 ± 1 US gpm)	47 ± 3 L/min (12 ± 1 US gpm)
Minimum Oil Cooler Flow	110 L/min (29 US gpm)
Pressures
"P1" Pressure	P2 + 335± 70 kPa (P2 + 49 ± 10 psi)	P2 + 290 ± 70 kPa (P2 + 42 ± 10 psi)
"P2" Pressure	1930 ± 170 kPa (280 ± 25 psi)	1930 ± 170 kPa (280 ± 25 psi)
"P3" Pressure (1)		1020 ± 140 kPa (148 ± 20 psi)
Lubrication Pressure	230± 25 kPa (33± 5 psi)

(1)	The transmission is in the FORWARD 1 position. The oil cooler flow is restricted.

Check of the Torque Converter Inlet Relief Valve

Table 8

Check of the Torque Converter Inlet Relief Valve

Input Speed (850 ± 25 rpm)

_______kPa _______psi

Low Idle Pressure Checks

Table 9

Low Idle Pressure Checks			Input Speed (850 ± 25 rpm)
Gear Range	N	F1	F2	F3	F4	R1	R2	R3
Input Flow
"P1" Pressure
"P2" Pressure

High Idle Pressure Checks

Table 10

High Idle Pressure Checks			Input Speed (2200 ± 25 rpm)
Gear Range	N	F1	F2	F3	F4	R1	R2	R3
Input Flow
Oil Cooler Flow
"P1" Pressure
"P2" Pressure
Lubrication Pressure

Contamination Control

Table 11

ISO Particle Count

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

________/________Particle Count

Table 12

______________________________________ Technician

______________________________________ Supervisor