Bench Test Procedure for a 414E, 416E, 416F, 420E, 420F, 422E, 422F, 428E, 428F, 430E, 430F, 432E, 432F, 434E, 434F, 442E, 444E, 444F, 450E and 450F Backhoe Loader Transmission (Standard Shift){3030} Caterpillar

Backhoe Loader:

414E (S/N: ELB1-UP; TMS1-UP)

416 Series E (S/N: LMS1-UP)

416E (S/N: SHA1-UP; BWC1-UP; CBD1-UP; MFG1-UP)

416F (S/N: KSF1-UP; LWT1-UP)

420E (S/N: PRA1-UP; PHC1-UP; HLS1-UP; KMW1-UP)

420F (S/N: LTG1-UP; LKH1-UP; JWJ1-UP; SKR1-UP)

422E (S/N: HBE1-UP; DSK1-UP; MAW1-UP)

422F (S/N: LRH1-UP)

428E (S/N: DXC1-UP; DPH1-UP; SNL1-UP)

428F (S/N: LBH1-UP; RAK1-UP; SJW1-UP)

430E (S/N: SCD1-UP; RLN1-UP; DDT1-UP; EAT1-UP)

430F (S/N: RDF1-UP; LNH1-UP; RGS1-UP; LDY1-UP)

432E (S/N: JBA1-UP; BXE1-UP; RXS1-UP)

432F (S/N: SEJ1-UP; LNR1-UP)

434E (S/N: SEF1-UP)

434F (S/N: LDH1-UP; FLY1-UP)

442E (S/N: EME1-UP; PCR1-UP; GKZ1-UP)

444E (S/N: NBA1-UP; HXB1-UP)

444F (S/N: LJJ1-UP; FBN1-UP)

450E (S/N: LYR1-UP)

450F (S/N: HJR1-UP)

Introduction

© 2012 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 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

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.

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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.

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.

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.

Installation Procedure

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Illustration 1	g01034238
Typical example

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

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Illustration 2	g01034239
Typical example

2. Install Tooling (A) on the opposite side of the transmission, as shown.

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Illustration 3	g01040740

3. Install Tooling (A) on the transmission, as shown.

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Illustration 4	g01040744

4. 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 5	g01040746

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

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Illustration 6	g01040747

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

6. Install Tooling (B) .

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Illustration 7	g01040748

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

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Illustration 8	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.

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

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Illustration 9	g01040768

9. 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 10	g01040770

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

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Illustration 11	g01040771

11. 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 12	g01040772

12. Align the transmission with the input drive shaft.

13. Connect the input drive shaft to Tooling (F) .

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Illustration 13	g01034268

14. Install the drive shaft guard.

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Illustration 14	g01034270
Typical example

15. Install Tooling (H) to Tooling (A), as shown.

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Illustration 15	g01034271
Typical example

16. Install Tooling (H), as shown.

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Illustration 16	g01034275
Typical example

17. Install pump drive (1) .

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Illustration 17	g01821793
Typical example

18. Install Tooling (J), as shown.

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Illustration 18	g01040794

19. Remove plate (2) .

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Illustration 19	g01040797

20. Remove screen filter (3) .

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Illustration 20	g01821853

21. Install Tooling (K) .

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Illustration 21	g01040806

22. Remove drain plug (4) .

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Illustration 22	g01821893

23. Install Tooling (L), as shown.

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Illustration 23	g01821933
Typical example

24. Install Tooling (M), as shown.

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Illustration 24	g01821953

25. Install Tooling (N), as shown.

26. Install Tooling (P), as shown.

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Illustration 25	g01822015

27. Install Tooling (R), as shown.

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Illustration 26	g01822053

28. Install Tooling (S) .

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Illustration 27	g01822055

29. Install Tooling (T) .

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Illustration 28	g01822073

30. Install Tooling (S) .

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Illustration 29	g01822096

31. Install Tooling (U) .

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Illustration 30	g01822114

32. Install Tooling (V), as shown.

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Illustration 31	g01822134

Note: Perform this step only on applicable transmissions.

33. Install Tooling (V), as shown.

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Illustration 32	g01822153

34. Install Tooling (V), as shown.

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Illustration 33	g01822154

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

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Illustration 34	g01822160

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

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Illustration 35	g01822164

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

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Illustration 36	g01822173
Torque converter outlet

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

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Illustration 37	g01822193
Inlet for the transmission lubrication oil

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

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Illustration 38	g01040859
Lubrication for the spindle

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

40. 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 39	g01040864
Transmission lubrication pressure tap

41. Connect a pressure gauge to pressure tap (11).

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Illustration 40	g01040870
(12) Pump pressure tap (13) Torque converter pressure tap

42. Connect two pressure gauges to pressure taps (12) and (13).

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Illustration 41	g01040874
AWD clutch pressure tap

Note: Perform this step only on applicable transmissions.

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

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Illustration 42	g01040877
(15) Forward clutch pressure tap (16) Reverse clutch pressure tap

44. Connect two pressure gauges to pressure taps (15) and (16).

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Illustration 43	g01040885
Cable connector "1-A" for "FORWARD" solenoid (17) Cable connector "2-B" for "REVERSE" solenoid (18)

45. Connect Tooling (W), as shown.

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Illustration 44	g01457869
Tooling (W)

46. Connect Tooling (W) to a power source. Refer to Tool Operating Manual, NEHS0996 for the correct operating instructions.

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Illustration 45	g01822214

47. Connect Tooling (W) to a suitable location, as shown.

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Illustration 46	g01040891

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

Test Procedure

Solenoid Test

1. Make sure that the harness is properly connected.

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

3. Record the values in Table 9.

Start Checks

Note: Refer to Testing and Adjusting, RENR6474, "414E, 416E, 420E, 422E, 428E, 430E, 432E, 434E, 442E, and 444E Backhoe Loaders Transmission (Standard Shift)" or Testing and Adjusting, UENR2302, "416F, 420F, 422F, 428F, 430F, 432F, and 434F Backhoe Loaders Transmission (Standard Shift)" 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.

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Illustration 47	g02720621

2. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1000 ± 25 rpm.

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

4. Stop the input rotation.

Torque Converter Relief Valve Check

1. With the transmission in the NEUTRAL position, adjust the input rotation to 1000 ± 25 rpm.

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

3. Open Tooling (T) .

4. Record the torque converter relief valve pressure in Table 10.

5. Verify the test point with the values in Table 4.

Low Idle Pressure Checks

1. With the shuttle lever in the NEUTRAL position, adjust the input rotation to 1000 ± 25 rpm.

2. Record the pump flow, lubrication flow, pump pressure, and the lubrication pressure in Table 11.

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

High Idle Pressure Checks

1. With the transmission in the NEUTRAL position, adjust the input rotation to 1600 ± 25 rpm.

2. Record the pump flow, lubrication flow, pump pressure, and the lubrication pressure in Table 12.

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

4. With the input speed at 1600 ± 25 rpm, shift the transmission to the FORWARD. Record the pressure in Table 13.

5. Shift the transmission to the NEUTRAL position.

6. With the input speed at 1600 ± 25 rpm, shift the transmission to the REVERSE position. Record the pressure in Table 13.

7. Verify the test points with the values in Table 5.

8. Shift the transmission to the NEUTRAL position.

Transmission Synchronization Check

1. Adjust input rotation to 1000 ± 25 rpm.

2. Engage the FORWARD clutch with the all wheel drive solenoid .

3. Engage FOURTH gear. Shift sequentially through the gears until NEUTRAL is reached.

4. From the NEUTRAL position, engage the REVERSE solenoid. Shift sequentially through the gears until FOURTH gear is reached.

5. Evaluate the gear synchronization and the transmission noise in each of the gears. Record findings in Table 14.

6. 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 48	g01822233

1. Install Tooling (X), as shown.

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Illustration 49	g01034903
Tooling (X)

Note: Adjust Tooling (X) to 10 VDC and 2.5 amp to actuate the all wheel drive solenoid.

2. Adjust input rotation to 1600 ± 25 rpm.

3. Shift the transmission to the NEUTRAL position.

4. In order to engage the all wheel drive solenoid, turn on Tooling (X) .

5. Record the pressure of the all wheel drive clutch in Table 15.

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

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Illustration 50	g01822235
Typical example Tooling (Y)

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Illustration 51	g01822254

7. Record the output speed of both front and rear drive shafts in each of the four FORWARD and four REVERSE gears in Table 16.

8. Verify the test points with the values in Table 6 and Table 7.

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 17.

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

Specifications

Directional Clutch Pressure Test

All Wheel Drive System Check

Transmission Bench Test Data Sheet

Solenoid Test

Torque Converter Relief Valve

Low Idle Pressure Checks

High Idle Pressure Checks

Directional Clutch Pressure Test

Transmission Gear Synchronization Check

All Wheel Drive System Check

ISO Particle Count