Bench Test Procedure for a 420D, 420D IT AWS, 420E, 420F, 428D NF ST, 428D PARA LIFT, 428F, 430D, 430D AWS, 430D IT, 430D IT AWS, 430E, 430F, 432D, 432E, 432F, 434E, 434F, 438D, 442D AWS, 442E, 444E, 444F, 450E, and 450FBackhoe Loader Transmission (P Caterpillar

Backhoe Loader:

420D (S/N: C2C1-UP)

420D IT AWS (S/N: C8A1-UP)

420E (S/N: PRA1-UP; PHC1-UP; GAN1-UP; HLS1-UP; KMW1-UP)

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

428D NF,ST (S/N: S1K1-UP)

428D PARA LIFT (S/N: S9D1-UP)

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

430D (S/N: C3J1-UP)

430D AWS (S/N: C7E1-UP)

430D IT (S/N: C5B1-UP)

430D IT, AWS (S/N: C9P1-UP)

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

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

432D (S/N: S6B1-UP; S6H1-UP)

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

432F (S/N: SEJ1-UP; LNR1-UP; PXR1-UP)

434E (S/N: SXB1-UP; FSH1-UP; SJL1-UP)

434F (S/N: LDH1-UP; MTR1-UP; FLY1-UP)

438D (S/N: S8J1-UP; S8M1-UP)

442D AWS (S/N: S4T1-UP)

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

444E (S/N: NBA1-UP; HXB1-UP; LBE1-UP)

444F (S/N: LJJ1-UP; FBN1-UP; JXR1-UP)

450E (S/N: EBL1-UP; LYR1-UP)

450F (S/N: HJR1-UP)

Introduction

© 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:

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

• Knowledge Network

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.

Illustration 1	g02139237

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.

Tools Needed

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

Show/hide table



Illustration 2	g01034238

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

Show/hide table



Illustration 3	g01034239

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

Show/hide table



Illustration 4	g01034241

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

Show/hide table



Illustration 5	g01034245

4. Use a hoist to install the transmission on the test bench. The weight of the transmission is 227 kg (500 lb).

Show/hide table



Illustration 6	g01034253

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

Show/hide table



Illustration 7	g01034254

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

6. Install Tooling (B) .

Show/hide table



Illustration 8	g01034258

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

Show/hide table



Illustration 9	g01034259

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) .

Show/hide table



Illustration 10	g01034263

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.

Show/hide table



Illustration 11	g01034265

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

Show/hide table



Illustration 12	g01034266

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) .

Show/hide table



Illustration 13	g01034267

12. Align the transmission with the input drive shaft.

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

Show/hide table



Illustration 14	g01034268

14. Install the drive shaft guard.

Show/hide table



Illustration 15	g01034270

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

Show/hide table



Illustration 16	g01034271

16. Install Tooling (H), as shown.

Show/hide table



Illustration 17	g01034275

17. Install pump drive (1) .

Show/hide table



Illustration 18	g01909576

18. Install Tooling (J), as shown.

Show/hide table



Illustration 19	g01034278

19. Remove plate (2) .

Show/hide table



Illustration 20	g01034279

20. Remove screen filter (3) .

Show/hide table



Illustration 21	g01909596

21. Install Tooling (K) .

Show/hide table



Illustration 22	g01034281

22. Remove drain plug (4) .

Show/hide table



Illustration 23	g01909613

23. Install Tooling (L), as shown.

Show/hide table



Illustration 24	g01909695

24. Install Tooling (M), as shown.

Show/hide table



Illustration 25	g01909714

25. Install Tooling (N), as shown.

26. Install Tooling (P), as shown.

Show/hide table



Illustration 26	g01909753

27. Install Tooling (R), as shown.

Show/hide table



Illustration 27	g01909755

28. Install Tooling (S).

29. Install Tooling (T) .

Show/hide table



Illustration 28	g01909835

30. Install Tooling (U) .

Show/hide table



Illustration 29	g01909854

31. Install Tooling (S) .

Show/hide table



Illustration 30	g01909860

32. Install Tooling (S) .

Show/hide table



Illustration 31	g01909865

33. Install Tooling (S) .

Show/hide table



Illustration 32	g01909886

34. Install Tooling (S) .

Show/hide table



Illustration 33	g01909889

35. Install Tooling (S) .

Show/hide table



Illustration 34	g01909891

36. Install Tooling (S) .

Show/hide table



Illustration 35	g01909893

37. Install Tooling (V), as shown.

Show/hide table



Illustration 36	g01909895

38. Install Tooling (W) on Tooling (V), as shown.

Show/hide table



Illustration 37	g01909914

39. Install Tooling (V), as shown.

Show/hide table



Illustration 38	g01909953

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

Show/hide table



Illustration 39	g01909956

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

Show/hide table



Illustration 40	g01910007

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

Show/hide table



Illustration 41	g01910044
Torque Converter Outlet

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

Show/hide table



Illustration 42	g01910046
Inlet for the Transmission Lubrication Oil

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

Show/hide table



Illustration 43	g01034471
Lubrication for the Spindle

45. Connect lube line (10) from the test bench to Tooling (D). Maintain an oil pressure of 275 kPa (40 psi).

Show/hide table



Illustration 44	g01040969
Pump Pressure Tap (11) . Torque Converter Pressure Tap (12) .

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

46. Connect two pressure gauges to pressure taps (11) and (12).

Show/hide table



Illustration 45	g01034486
Transmission Lubrication Pressure Tap

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

Show/hide table



Illustration 46	g01034487
AWD Clutch Pressure Tap

Note: Perform this step only on applicable transmissions.

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

Show/hide table



Illustration 47	g01034488
Forward Low Clutch Pressure Tap

49. Connect a pressure gauge to pressure tap (15) .

Show/hide table



Illustration 48	g01034491
Forward High Clutch Pressure Tap

50. Connect a pressure gauge to pressure tap (16) .

Show/hide table



Illustration 49	g01034511
Reverse Clutch Pressure Tap

51. Connect a pressure gauge to pressure tap (17) .

Show/hide table



Illustration 50	g01034513
No. 3 Clutch Pressure Tap

52. Connect a pressure gauge to pressure tap (18) .

Show/hide table



Illustration 51	g01034514
No. 2 Clutch Pressure Tap

53. Connect a pressure gauge to pressure tap (19) .

Show/hide table



Illustration 52	g01034515
No. 1 Clutch Pressure Tap

54. Connect a pressure gauge to pressure tap (20) .

Show/hide table



Illustration 53	g01910617
Cable connector (4-D) for No. 4 "FIRST SPEED" solenoid

55. Connect Tooling (U), as shown.

Show/hide table



Illustration 54	g01034517
Cable connector (5-E) for No. 5 "SECOND SPEED" solenoid (13) Cable connector (6-F) for No. 6 "THIRD SPEED" solenoid (14)

56. Connect Tooling (X), as shown.

Show/hide table



Illustration 55	g01034518
Cable connector (2-B) for No. 2 "REVERSE" solenoid (15)

57. Connect Tooling (X), as shown.

Show/hide table



Illustration 56	g01034519
Cable connector (1-A) for No. 1 "FORWARD HIGH" solenoid (16) Cable connector (3-C) for No. 3 "FORWARD LOW" solenoid (17)

58. Connect Tooling (X), as shown.

Show/hide table



Illustration 57	g01457869
Tooling (X)

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

Show/hide table



Illustration 58	g01910654

60. Connect Tooling (X) to a suitable location, as shown.

Show/hide table



Illustration 59	g01034522

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

Test Procedure

Solenoid Test

1. Make sure that the harness is properly connected.

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

3. Record the values in Table 10.

Start Checks

Note: Refer to Testing and Adjusting, RENR6473, "420E, 430E, 432E, 434E, 442E, and 444E Backhoe Loaders Transmission (Power Shift)" or Testing and Adjusting, UENR2301, "420F, 428F, 430F, 432F, 434F, and 444F Backhoe Loaders Transmission (Power 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.

Show/hide table



Illustration 60	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

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

2. Use Tooling (W) to block the flow at the torque converter outlet.

3. Open Tooling (W) .

4. Record the torque converter relief valve pressure in Table 11.

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

Low Idle Pressure Checks

1. With the transmission 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 12.

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

Medium 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 13.

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

4. With the input speed at 1600 ± 25 rpm, shift the transmission through each FORWARD and REVERSE speed range. Record pressures in Table 14 for each position.

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

6. Shift the transmission to the NEUTRAL position.

High Idle Pressure Checks

1. With the transmission in the NEUTRAL position, adjust the input rotation to 2400 ± 25 rpm.

2. Record the pump flow, lubrication flow, pump pressure, and the lubrication pressure in Table 15.

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

4. Stop the input rotation.

All Wheel Drive System Check

Note: Perform this test only on applicable transmissions.

Show/hide table



Illustration 61	g01911333

1. Install Tooling (Y), as shown.

Show/hide table



Illustration 62	g01034903
Tooling (Y)

Note: Adjust Tooling (Y) to 10 VDC and 2.5 amp. This adjustment is needed 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 (Y) .

5. Record the pressure of the All Wheel Drive clutch in Table 16.

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

Show/hide table



Illustration 63	g01911340
Tooling (Z)

Show/hide table



Illustration 64	g01911343
Tooling (Z)

7. Record the output speed of both front and rear drive shafts in each of the five FORWARD and three REVERSE gears in Table 17.

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

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 18.

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

Specifications

All Wheel Drive System Check

Transmission Bench Test Data Sheet

Solenoid Test

Torque Converter Relief Valve

Low Idle Pressure Checks

Medium Idle Pressure Checks

High Idle Pressure Checks

All Wheel Drive System Check

ISO Particle Count