Bench Test Procedure for a 415F2, 416F2, 420F2, 422F2, 427F2, 428F2, 430F2, 432F2, and 434F2 Backhoe Loader Standard Shift Transmission {3030, 3065, 3073, 3167} Caterpillar

Backhoe Loader

415F2 (S/N: HWA1-UP)

415F2 IL (S/N: PF41-UP)

416F2 (S/N: LYA1-UP; HWB1-UP; LBF1-UP)

420F2 (S/N: LBS1-UP)

420F2 IT (S/N: LYC1-UP; HWD1-UP)

420F2 ST (S/N: LYB1-UP; HWC1-UP)

422F2 (S/N: LYF1-UP)

427F2 (S/N: HWK1-UP)

428F2 (S/N: LYG1-UP; HWN1-UP)

430F2 IT (S/N: LYE1-UP; HWG1-UP)

430F2 ST (S/N: LYD1-UP; HWE1-UP)

432F2 (S/N: LYJ1-UP; HWP1-UP)

434F2 (S/N: LYK1-UP; HWR1-UP)

Introduction

© 2017 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar 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 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 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 technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

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 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.

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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.

Tools Needed

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

Installation Procedure

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Illustration 3	g03813143

1. Install Tooling (A) onto test bed.
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   Illustration 4	g03813146

2. Install Tooling (B) onto Tooling (A).
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   Illustration 5	g03813155
   Lube (in)

3. Remove Fitting (1).
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   Illustration 6	g03813159

4. Install Tooling (C).
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   Illustration 7	g03813468

5. Install Tooling (D) on both sides of the transmission.
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   Illustration 8	g03813483

6. Use a hoist to install the transmission on the test stand. The weight of the transmission is 250 kg (550 lb).
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   Illustration 9	g03813489

7. Install Tooling (E) to secure Tooling (B) to Tooling (A).

   Note: Over-tightening Tooling (E) can jeopardize the tightening ability of the castle nuts later in this section.

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   Illustration 10	g03813494

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   NOTICE
   The Torque Converter has a shallow spline engagement. Use extreme caution when performing 8 through 10 so that Torque Converter does not fall out of the transmission.

8. Carefully remove Flex Plate (2).
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   Illustration 11	g03813522

9. Install Tooling (F) to the transmission.
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   Illustration 12	g03813577

10. Install Tooling (G).
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    Illustration 13	g03813529

11. Install Tooling (H) to the Torque Converter.
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    Illustration 14	g03813536

12. Install Tooling (J) to Tooling (H).
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    Illustration 15	g03813692

13. Install Tooling (K) to the input end of the transmission.
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    Illustration 16	g03813717

14. Use a hoist to install Tooling (L) onto Tooling (K).
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    Illustration 17	g03374665

15. Adjust and tighten the collet on Tooling (L).

    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 18	g03813725

16. Install Tooling (M).
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    Illustration 19	g03813728

17. Install Tooling (N) onto Tooling (M).
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    Illustration 20	g03798037

18. Use the hoist and pry bars to align and connect the input drive shaft to Tooling (N).
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    Illustration 21	g03798038

19. Close and latch the drive shaft guard.
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    Illustration 22	g03375318

20. Tighten all four castle nuts and jack bolts on Tooling (A).

21. Tighten Tooling (E) to prevent movement of the transmission during testing.
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    Illustration 23	g03813731

22. Remove Plug (3)
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    Illustration 24	g03813733
    System Pressure

23. Install Tooling (P).
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    Illustration 25	g03813735

24. Remove Plug (4).
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    Illustration 26	g03813737
    FORWARD Clutch

25. Install Tooling (P).
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    Illustration 27	g03813741

26. Remove Plug (5).
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    Illustration 28	g03814010
    Top: Differential Lock Bottom: All Wheel Drive

27. Install Tooling (P).
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    Illustration 29	g03814033

28. Remove Plug (6).
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    Illustration 30	g03814041
    REVERSE Clutch

29. Install Tooling (P).
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    Illustration 31	g03814047

30. Remove Fitting (7).
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    Illustration 32	g03814057
    Torque Converter

31. Install Tooling (Q).
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    Illustration 33	g03814065

32. Remove Plug (8).
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    Illustration 34	g03814071
    Gravity Feed

33. Install Tooling (R).
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    Illustration 35	g03814080
    Overflow Port

34. Install Tooling (S).
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    Illustration 36	g03814085

35. Install Tooling (T).
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    Illustration 37	g03814086
    Torque Converter

36. Install Tooling (U) to Tooling (Q).
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    Illustration 38	g03814096

37. Install Tooling (V).
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    Illustration 39	g03814124
    Spindle Lube

38. Connect Hose Assembly (9) to Tooling (L).
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    Illustration 40	g03814128
    Gravity Feed

39. Install Tooling (W) to the end of Hose Assembly.
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    Illustration 41	g03814130
    Gravity Feed

40. Connect Hose Assembly (10) from Gravity Feed to Tooling (R).
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    Illustration 42	g03814481
    Torque Converter

41. Connect Hose Assembly (11) from Tooling (U) to Flowmeter 1 (in).
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    Illustration 43	g03814488
    Lube (in)

42. Connect Hose Assembly (12) from Flowmeter 1 (out) to Tooling (C).
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    Illustration 44	g03814505
    (13) FORWARD Clutch Pressure ( 0 - 3447 kPa (0 - 500 psi)) (14) Lube Pressure ( 0 - 965 kPa (0 - 140 psi))

43. Connect Pressure gauges to Pressure taps (13) and (14).
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    Illustration 45	g03814804
    0 - 3447 kPa (0 - 500 psi) (15) REVERSE Clutch Pressure

44. Connect a Pressure gauge to Pressure tap (15).
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    Illustration 46	g03814842
    (16) System Pressure ( 0 - 3447 kPa (0 - 500 psi)) (17) Torque Converter Pressure ( 0 - 965 kPa (0 - 140 psi))

45. Connect Pressure gauges to Pressure taps (16) and (17).
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    Illustration 47	g03814847
    0 - 3447 kPa (0 - 500 psi) (18) All Wheel Drive Pressure

46. Connect a Pressure gauge to Pressure tap (18).
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    Illustration 48	g03818076
    Left - FORWARD Clutch Right - REVERSE Clutch

47. Connect Tooling (X) to Solenoids.
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    Illustration 49	g03818732

48. Assemble Tooling (X).

Test Procedure

Start Check

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 50	g02720621

2. With the transmission in NEUTRAL, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1000 ± 20 rpm.

3. Energize the FORWARD Solenoid. Shift sequentially through gears until FOURTH gear is reached.

4. Return back to NEUTRAL position.

5. Engage the REVERSE Solenoid. Shift sequentially through gears until FOURTH gear is reached.

6. Return back to NEUTRAL position.

7. When switching gears, listen for abnormal noises.

   Note: If abnormal noises occur, stop input rotation and check transmission and test bench connections. If noise still occurs, consult your rebuild technician.

Torque Converter Relief Valve Check

1. With the transmission in NEUTRAL position, adjust the input rotation to 1000 ± 20 rpm.

2. Use Tooling (U) to block flow temporarily at the Torque Converter outlet.

   Note: To prevent running the transmission dry, the maximum block time is 10 seconds.

3. Record the Torque Converter outlet pressure in Table 5.

4. Open Tooling (U).

5. Verify the Torque Converter outlet pressure with Table 5.

Low Idle Checks

1. With the transmission in NEUTRAL position, adjust the input rotation to 1000 ± 20 rpm.

2. Record Pump Flow, Lube Flow, System Pressure, and Lube Pressure in Table 6.

3. Verify values with Table 6.

High Idle Checks

1. With the transmission in NEUTRAL position, adjust the input rotation to 1600 ± 20 rpm.

2. Record Pump Flow, Lube Flow, System Pressure, and Lube Pressure in Table 7.

3. Verify values with Table 7.

4. With the input rotation at 1600 ± 20 rpm, energize the FORWARD Solenoid.

5. Record the FORWARD clutch pressure in Table 7.

6. Verify the value with Table 7.

7. With the input rotation at 1600 ± 20 rpm, energize the REVERSE Solenoid.

8. Record the REVERSE clutch pressure in Table 7.

9. Verify the value with Table 7.

All Wheel System Drive Test

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Illustration 51	g03814918

1. Connect Tooling (X) to the All Wheel Drive Solenoid, as shown.

2. Adjust Tooling (X) to 12 V - 1.5 Amps.

3. With the transmission in NEUTRAL, adjust the input rotation to 1600 ± 20 rpm.

4. Use Tooling (X) to engage All Wheel Drive Solenoid.

5. Record the pressure of the All Wheel Drive clutch in Table 8.

6. Verify the value in 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 10.

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

Transmission Bench Test Data Sheet

Torque Converter Relief Valve Check

Low Idle Checks

High Idle Check

All Wheel System Drive Test

Contamination Control