Bench Test Procedure for a 966K and a 972K Wheel Loader Transmission{3030, 3073, 3139} Caterpillar

Wheel Loader:

966K (S/N: PBG1-UP; TFS1-UP)

972K (S/N: PEM1-UP; Z4W1-UP)

Introduction

© 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 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

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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

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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 in order 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.

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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 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.

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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.

Installation Procedure

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1. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1041 kg (2297 lb).

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2. Install Tooling (A) to the output end of the transmission.

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3. Install Tooling (B) on the torque converter.

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

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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.

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

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6. Tighten the collet on Tooling (D) to connect Tooling (D) to Tooling (B) .

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

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Illustration 10	g00993305

8. 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 (F) .

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9. Align the transmission with the input drive shaft.

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

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11. Install the drive shaft guard.

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12. Tighten all four castle nuts and jack bolts.

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13. Install Tooling (H) to the output end of the transmission.

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14. Install Tooling (H) to the input end of the transmission.

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15. Remove two covers (1) .

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16. Remove magnetic filter (2) .

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17. Install Tooling (T). Orient the slot.

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18. Install Tooling (J) .

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19. Install Tooling (K) .

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20. Install Tooling (L) .

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21. Install Tooling (M) .

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22. Connect Tooling (N) to Tooling (M) .

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23. Install Tooling (O) .

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24. Connect hose assembly (3) from the gravity feed pump supply to Tooling (J) .

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Illustration 26	g02451061
Outlet for Transmission Oil Pump

25. Connect hose assembly (4) from Tooling (K) to No. 1 flow meter inlet.

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Illustration 27	g00993321
Inlet For The Main Relief Valve And Clutch Supply Rail

26. Connect hose assembly (5) from the outlet of the No. 1 flow meter to Tooling (L) .

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Converter Outlet

27. Connect hose assembly (6) from Tooling (N) to No. 2 flow meter inlet.

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Inlet For The Transmission Lubrication Oil

28. Connect hose assembly (7) from the outlet of the No. 2 flow meter to Tooling (U) .

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29. Connect lube line (8) from the test bench to Tooling (D). Maintain an oil pressure of 275 kPa (40 psi).

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Transmission Oil Pump Pressure

30. Connect a pressure gauge to pressure tap (9) .

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Converter Inlet Oil Pressure

31. Connect a pressure gauge to pressure tap (10) .

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Torque Converter Pressure

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

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Transmission Lubrication Pressure

33. Connect a pressure gauge to pressure tap (12) .

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Illustration 35	g00993329
(13) No. 6 clutch (14) No. 5 clutch (15) No. 4 clutch (16) No. 3 clutch (17) No. 2 clutch (18) No. 1 clutch

34. Connect six pressure gauges to pressure taps (13), (14), (15), (16), (17), and (18) .

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Illustration 36	g01013540
Cable connector (1-A) for No. 1 clutch solenoid (24) Cable connector (2-B) for No. 2 clutch solenoid (23) Cable connector (3-C) for No. 3 clutch solenoid (22) Cable connector (4-D) for No. 4 clutch solenoid (21) Cable connector (5-E) for No. 5 clutch solenoid (20) Cable connector (6-F) for No. 6 clutch solenoid (19)

35. Connect Tooling (P) to six clutch solenoids.

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36. Connect Tooling (P) to a suitable location.

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Tooling (P)

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Tooling (P)

37. Connect Tooling (P) to a power source. Refer to Tool Operating Manual, NEHS0644 or Tool Operating Manual, NEHS0996 for the correct operating instructions.

Test Procedure

TA3 Navigation

1. Select "Wheel Loaders".

2. Select "966G-24V" or "972G-24V".

Harness Test (TA3 only)

1. Make sure that the harness is properly connected.

2. Use Tooling (P) 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 (P) 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, KENR6471, "966K Wheel Loader and 972K 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.

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2. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 960 ± 45 rpm.

3. The input flow should be 61 ± 4 L/min (16 ± 1 US gpm). The pump supply pressure should be minimum 2415 kPa (350 psi).

   Note: Adjust the input rotation to produce the correct input flow.

4. Shift the transmission through all speed ranges to eliminate air from the transmission controls.

5. Confirm the correct clutch engagement with Table 4.
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   Table 4

   Clutch Engagement Check
   Gear	Cl 1	Cl 2	Cl 3	Cl 4	Cl 5	Cl 6
   N			X
   F1		X				X
   F2		X			X
   F3		X		X
   F4		X	X
   R1	X					X
   R2	X				X
   R3	X			X
   R4	X		X

6. The lube pressure should be minimum 30 kPa (4 psi).

   Note: If there is no lube pressure after 3 seconds, stop input rotation and check connections on test bench and transmission.

7. Record the values in Table 8.

8. Adjust the input speed to 2200 ± 80 rpm.

9. Refer to Table 7 for the correct supply pressure. Adjust the transmission hydraulic control relief valve, if necessary.

10. The correct lube pressure for FORWARD 2 is 335 kPa (49 psi). The correct lube pressure for all other gear ranges is 364 kPa (53 psi).

11. Adjust the transmission hydraulic control relief valve, if necessary.

12. Record the value in Table 8.

Torque Converter Inlet Pressure

1. Adjust the input speed to 965 ± 45 rpm.

2. Shift the transmission to FORWARD 1.

3. Use Tooling (N) to block flow temporarily at the converter outlet.

4. The converter inlet pressure must be 1000 ± 50 kPa (145 ± 7 psi).

5. Open the lube flow.

6. Record the value in Table 9.

Clutch Leakage Check

Note: Measure the leakage in each gear range. The input flow should be approximately 102 L/min (27 US gpm) when the input speed is 1700 ± 80 rpm.

1. Adjust the input rotation to 965 ± 45 rpm.

2. Shift the transmission to the FORWARD 1 position.

3. Adjust the input rotation to 1700 ± 80 rpm.

4. Record the input flow in Table 10.

5. Record the lube flow in Table 10.

6. The leakage is obtained by subtracting the lube flow from the input flow.

7. Record the calculation in Table 10.

8. Adjust the input rotation to 965 ± 45 rpm.

9. Shift the transmission through positions FORWARD 2, FORWARD 3, FORWARD 4, REVERSE 1, REVERSE 2, REVERSE 3, REVERSE 4, and NEUTRAL. Repeat Steps 3 through 8 for each gear range.

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

10. The leakage for NEUTRAL, FIRST, THIRD, and FOURTH gear ranges should be between 10 L/min (2.6 US gpm) and 26 L/min (6.9 US gpm).

11. The leakage for FORWARD 2 and REVERSE 2 gear ranges should be between 16 L/min (4.2 US gpm) and 32 L/min (8.5 US gpm).

12. The difference of leakage between NEUTRAL, FIRST, THIRD, and FOURTH gear ranges should be within 3.8 L/min (1 US gpm) of each other.

Lube Circuit Check

1. Adjust the input rotation until the lube flow is 76 ± 4 L/min (20 ± 1 US gpm). Maintain this flow during this check.

2. Shift the transmission to FORWARD 3.

3. The lube pressure should be minimum 61 kPa (9 psi)and maximum 113 kPa (16 psi).

4. Record the value in Table 11.

Speed Sensor Test

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Illustration 41	g01013541
Tooling (Q)

1. Connect Tooling (Q) to input speed sensor (25) .

2. Adjust the input rotation to 965 ± 45 rpm.

3. Shift the transmission to FORWARD 2.

4. Adjust the input rotation until the frequency that is measured by Tooling (Q) matches the value in Table 12.

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Illustration 42	g00993349
(25) Input Speed Sensor (26) Output Speed Sensor "No. 1" (27) Output Speed Sensor "No. 2"

5. Use Tooling (Q) to measure the sensor signal voltage. Measure each speed sensor.

   Note: The voltage for each sensor must be equal to or greater than the values in Table 12.

6. Record the values in Table 13.

7. Verify the test points with the values in Table 12.

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 14.

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

Transmission Bench Test Data Sheet

Solenoid Test

Start Checks

Torque Converter Inlet Pressure

Clutch Leakage Check

Lube Circuit Check

Speed Sensor Test

ISO Particle Count