Bench Test Procedure for 420F2, 426F2, 427F2, 428F2, 430F2, 432F2, 434F2, 440, 444F2, and 450 Backhoe Loader Transmissions {3030, 3073, 3139, 5051} Caterpillar

Backhoe Loader

420F2 (S/N: NSB1-UP)

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

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

426 F2 (S/N: EJ21-UP; DJ41-UP; EJ41-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)

440 (S/N: DC91-UP)

444F2 (S/N: LYL1-UP; HWS1-UP)

450 (S/N: KJH1-UP)

Introduction

© 2018 Caterpillar All Rights Reserved. This document 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 document 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 document 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 document 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 document 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 additional filtering can affect pressure. The required tools that are listed in Table 3 were used to develop this test procedure. These tools are suggested and may very depending on availability and bench configuration.

Installation Procedure

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Illustration 3	g01034238

1. Install Tooling (A) on the transmission.
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2. Install Tooling (A) on the opposite side of the transmission.
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3. Install Tooling (A) on the transmission.
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   Illustration 6	g01034245

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 7	g01034253

5. Install Tooling (B) on the torque converter.
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   Illustration 8	g01034254

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

6. Install Tooling (B).
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   Illustration 9	g01034258

7. Install Tooling (C) to the transmission case.
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   Illustration 10	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).
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   Illustration 11	g01034263

9. 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 12	g01034265

10. Install Tooling (E) to the input shaft of Tooling (D).
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    Illustration 13	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).

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    Illustration 14	g01034267

12. Align the transmission with the input drive shaft.

13. Connect the input drive shaft to Tooling (F).
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    Illustration 15	g01034268

14. Install the drive shaft guard.
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    Illustration 16	g03802221

15. Tighten all four castle nuts and jack bolts.
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    Illustration 17	g01034270

16. Install Tooling (H) to Tooling (A).
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    Illustration 18	g01034271

17. Install Tooling (H).
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    Illustration 19	g01034275

18. Install pump drive (1).
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    Illustration 20	g01909576

19. Install Tooling (J).
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    Illustration 21	g01034278

20. Remove plate (2).
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    Illustration 22	g01034279

21. Remove screen filter (3).
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    Illustration 23	g01909596

22. Install Tooling (K).
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    Illustration 24	g01034281

23. Remove drain plug (4).
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    Illustration 25	g01909613

24. Install Tooling (L).
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    Illustration 26	g01909695

25. Install Tooling (M).
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    Illustration 27	g01909714

26. Install Tooling (N).

27. Install Tooling (P).
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    Illustration 28	g01909753

28. Install Tooling (R).
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    Illustration 29	g01909755

29. Install Tooling (S).

30. Install Tooling (T).
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    Illustration 30	g01909835

31. Install Tooling (U).
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    Illustration 31	g01909854

32. Install Tooling (S).
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33. Install Tooling (S).
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34. Install Tooling (S).
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35. Install Tooling (S).
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36. Install Tooling (S).
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    Illustration 36	g01909891

37. Install Tooling (S).
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    Illustration 37	g01909893

38. Install Tooling (V).
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    Illustration 38	g01909895

39. Install Tooling (W) on Tooling (V).
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    Illustration 39	g01909914

40. Install Tooling (V).
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    Illustration 40	g01909953

41. Connect hose assembly (5) from the pump supply to Tooling (K).
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    Illustration 41	g01909956

42. Connect hose assembly (6) from the No. 1 flow meter inlet to Tooling (P).
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    Illustration 42	g01910007

43. Connect hose assembly (7) from the outlet of the No. 1 flow meter to Tooling (R).
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    Illustration 43	g01910044
    Torque Converter Outlet

44. Connect hose assembly (8) from the No. 2 flow meter inlet to Tooling (W).
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    Illustration 44	g01910046
    Inlet for the Transmission Lubrication Oil

45. Connect hose assembly (9) from the outlet of the No. 2 flow meter to Tooling (S).
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    Illustration 45	g01034471
    Lubrication for the Spindle

46. 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 46	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.

47. Connect two pressure gauges to pressure taps (11) and (12).
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    Illustration 47	g01034486
    Transmission Lubrication Pressure Tap

48. Connect a pressure gauge to pressure tap (13).
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    Illustration 48	g01034487
    AWD Clutch Pressure Tap

    Note: Perform this step only on applicable transmissions.

49. Connect a pressure gauge to pressure tap (14).
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    Illustration 49	g01034488
    Forward Low Clutch Pressure Tap

50. Connect a pressure gauge to pressure tap (15).
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    Illustration 50	g01034491
    Forward High Clutch Pressure Tap

51. Connect a pressure gauge to pressure tap (16).
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    Illustration 51	g01034511
    Reverse Clutch Pressure Tap

52. Connect a pressure gauge to pressure tap (17).
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    Illustration 52	g01034513
    No. 3 Clutch Pressure Tap

53. Connect a pressure gauge to pressure tap (18).
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    Illustration 53	g01034514
    No. 2 Clutch Pressure Tap

54. Connect a pressure gauge to pressure tap (19).
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    Illustration 54	g01034515
    No. 1 Clutch Pressure Tap

55. Connect a pressure gauge to pressure tap (20).
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    Illustration 55	g01910617
    Cable connector (4-D) for No. 4 "FIRST SPEED" solenoid

56. Connect Tooling (U).
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    Illustration 56	g01034517
    Cable connector (5-E) for No. 5 "SECOND SPEED" solenoid (13) Cable connector (6-F) for No. 6 "THIRD SPEED" solenoid (14)

57. Connect Tooling (X).
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    Illustration 57	g01034518
    Cable connector (2-B) for No. 2 "REVERSE" solenoid (15)

58. Connect Tooling (X).
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    Illustration 58	g01034519
    Cable connector (1-A) for No. 1 "FORWARD HIGH" solenoid (16) Cable connector (3-C) for No. 3 "FORWARD LOW" solenoid (17)

59. Connect Tooling (X).
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    Illustration 59	g01457869
    Tooling (X)

60. Connect Tooling (X) to a power source. Refer to Tool Operating Manual, NEHS0996 for the correct operating instructions.
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    Illustration 60	g01910654

61. Connect Tooling (X) to a suitable location.
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    Illustration 61	g01034522

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

Test Procedure

TA3 Navigation

1. Select "Backhoe Loaders".

2. Select “420F2-12V”, "426F2-12V", “427F2-12V”, “428F2-12V”, “430F2-12V”, “432F2-12V”, “434F2-12V”, "440-12V", “444F2-12V” or "450-12V".

Harness 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 11.

   Note: Do not continue with test until Harness Test passes.

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.
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   Illustration 62	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 to eliminate air from the transmission controls.

4. Verify clutch engagement with Table 4.
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   Table 4

   Clutch Engagement Check
   Gear	FWD LOW	FWD HI	REV	CL 1	CL 2	CL 3
   F1	X			X
   F2		X		X
   F3	X				X
   F4		X			X
   F5	X					X
   F6		X				X
   N
   R1			X	X
   R2			X		X
   R3			X			X

5. 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 12.

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

Low Idle 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 13.

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

Medium Idle 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 14.

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

4. With the input speed at 1600 ± 25 rpm, shift the transmission through each FORWARD and REVERSE speed range. Record pressures in Table 15 for each position.

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

6. Shift the transmission to the NEUTRAL position.

High Idle 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 16.

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

4. Stop the input rotation.

All Wheel Drive System Check

Note: Perform this test only on applicable transmissions.

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Illustration 63	g01911333

1. Install Tooling (Y).
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   Illustration 64	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. To engage the all wheel drive solenoid, turn on Tooling (Y).

5. Record the pressure of the All Wheel Drive clutch in Table 17.

6. Verify the test points with the values in Table 5.
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   Illustration 65	g01911340
   Tooling (Z)

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   Illustration 66	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 18.

8. Verify the test points with the values in Table 8 and Table 9.

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 19.

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 Checks

Medium Idle Checks

High Idle Checks

All Wheel Drive System Check

Contamination Control