- Wheel Loader:
- 950K (S/N: R4A1-UP; J5M1-UP; FER1-UP)
- 962K (S/N: T6A1-UP; FLL1-UP; X4T1-UP)
Introduction
| Revision | Summary of Changes in REHS3618 | |
| 02 | Standardized. | |
| 01 | Corrected Tools Needed table and Tool Operating Manual number. | |
© 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
- Dealer Solution Network
- Caterpillar Technical Representative
- Knowledge Network
| Machine Model | Transmission Arrangement |
| 950K | 324-7739 |
| 962K | 324-7738 |
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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| 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 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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| 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 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. |
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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.
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 1U-9584 | Rail As | 2 |
| 4C-9998 | Bracket | 2 | |
| 9U-6001 | Crossmember | 1 | |
| 6V-3669 | Bolt (M20X2.5X80 mm) | 4 | |
| 8T-3282 | Hard Washer | 4 | |
| 1D-4616 | Bolt (3/4-10X6.0 inch) | 4 7 |
|
| 2S-0115 | Hard Washer | 8 | |
| 2J-3506 | Full Nut | 4 | |
| B | 1U-5798 | Drive Adapter Gp | 1 |
| C | 1U-6698 | Spindle Adapter | 1 |
| 2J-5245 | Bolt (3/8-16X1.25 inch) | 6 | |
| 3B-4506 | Lockwasher | 6 | |
| D | 1U-5999 | Spindle Gp | 1 |
| 1A-1460 | Bolt (1/2-13X2.00 inch) | 4 | |
| 3B-4508 | Lockwasher | 4 | |
| E | 1U-6721 | Adapter (Drive) | 1 |
| F | 1U-9131 | Drive Adapter (Key) (3) | 1 |
| G | 1U-9359 | Drive Adapter (4) | 1 |
| H | 1U-9722 | Load Binder As (Ratchet Type) | 2 |
| T | 1U-9037 | Adapter (Oil Supply) | 1 |
| 4F-7390 | O-Ring Seal | 1 | |
| J | 235-4764 | Adapter | 1 |
| 8C-5212 | O-Ring Seal | 1 | |
| 140-5978 | Fitting | 1 | |
| 1U-9879 | Adapter (Quick Disconnect) | 1 | |
| 6V-7981 | Bolt (M10X1.50X70 mm) | 4 | |
| 5M-2894 | Hard Washer | 4 | |
| K | 1U-8301 | Fitting | 1 |
| 9U-7444 | Adapter As | 1 | |
| 8C-3206 | Half Flange | 2 | |
| 8C-9024 | Fitting As (Plain) | 1 | |
| 6V-3965 | Fitting As (Quick Disconnect) | 1 | |
| 4J-0520 | O-Ring Seal | 1 | |
| 6V-1820 | Bolt (M10X1.50X30 mm) | 4 | |
| 6V-5839 | Washer | 4 | |
| L | 1U-8304 | Fitting (45 Degree) | 1 |
| 9U-7444 | Adapter As | 1 | |
| 8C-3206 | Half Flange | 2 | |
| 8C-9024 | Fitting As (Plain) | 1 | |
| 6V-3965 | Fitting As (Quick Disconnect) | 2 | |
| 4J-0520 | O-Ring Seal | 1 | |
| 6V-1820 | Bolt (M10X1.5X30 mm) | 4 | |
| 6V-5839 | Washer | 4 | |
| M | 1U-8301 | Fitting | 1 |
| 9U-7445 | Adapter | 1 | |
| 1P-4578 | Half Flange | 2 | |
| 8C-9024 | Fitting As (Plain) | 1 | |
| 6V-3965 | Fitting As (Quick Disconnect) | 1 | |
| 4J-0520 | O-Ring Seal | 1 | |
| 6V-8197 | Bolt (M12X1.75X40 mm) | 4 | |
| 5P-8245 | Hard Washer | 4 | |
| N | 1U-9854 | Adapter | 1 |
| 4J-0524 | O-Ring Seal | 1 | |
| 8C-9024 | Fitting As (Plain) | 1 | |
| 6V-1820 | Bolt (M10X1.50X30 mm) | 2 | |
| 6V-5839 | Washer | 2 | |
| U | 8C-9024 | Fitting As (Plain) | 1 |
| 8C-9025 | Quick Coupler | 1 | |
| 3B-7749 | Fitting | 1 | |
| 120-6843 | Ball Valve | 1 | |
| P | 9U-7500 | Transmission Analyzer Tool Gp | 1 |
| OR | |||
| 277-2362 | Transmission Analyzer III Gp | 1 | |
| 306-0397 | Extension Cable | 1 | |
| 9U-7495 | Adapter Cable As (Wheel Loader) | 1 | |
| 1U-9480 | Cable Adapter | 6 | |
| Q | 146-4080 | Digital Multimeter | 1 |
| 5P-5677 | Electrical Wire | 1 | |
| 155-2270 | Connecting Plug Kit | 1 | |
| 186-3736 | Connector Socket | 2 | |
| R | 8T-0855 | Pressure Gauge (0 to 4,000 kPa (0 to 580 psi)) | 9 |
| 6V-4144 | Coupler | 9 | |
| S | 8T-0862 | Pressure Gauge (-100 to 500 kPa (-15 to 72 psi)) | 1 |
| 6V-4144 | Coupler | 1 | |
| ( 3 ) | This drive adapter is used with the small drive shaft. |
| ( 4 ) | This drive adapter is used with the large drive shaft. |
Installation Procedure
- Install Tooling (A) to the output end of the transmission.
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| Illustration 3 | g03872013 |
- Use a hoist to install the transmission on Tooling (A). The weight of the transmission is 1180 kg (2600 lb).
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| Illustration 4 | g02627410 |
- Install Tooling (B) on the torque converter.
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| Illustration 5 | g02627523 |
- Install Tooling (C) to the transmission case.
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| Illustration 6 | g02627586 |
- Install Tooling (D) on Tooling (C) .
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| Illustration 7 | g02627618 |
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.
- Tighten the collet on Tooling (D) to connect Tooling (D) to Tooling (B) .
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| Illustration 8 | g02627638 |
- Install Tooling (E) to the input shaft of Tooling (D) .
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| Illustration 9 | g02627716 |
- 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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| Illustration 10 | g02628516 |
- Align the transmission with the input drive shaft.
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| Illustration 11 | g02628600 |
- Connect the input drive shaft to Tooling (F) .
- Close and latch the drive shaft guard.
- Tighten all four castle nuts and jack bolts.
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| Illustration 12 | g03802221 |
- Install Tooling (H) to the input and output ends of the transmission.
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| Illustration 13 | g02628738 |
- Remove cover (1) .
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| Illustration 14 | g02628777 |
- Remove cover (1) .
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| Illustration 15 | g02628780 |
- Remove magnetic filter (2) .
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| Illustration 16 | g02628801 |
- Install Tooling (T). Orient the slot, as shown.
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| Illustration 17 | g03872021 |
- Install Tooling (J) .
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| Illustration 18 | g02628979 |
- Install Tooling (K) .
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| Illustration 19 | g02640621 |
- Install Tooling (L) .
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| Illustration 20 | g02640658 |
- Install Tooling (M) .
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| Illustration 21 | g02628998 |
- Connect Tooling (U) to Tooling (M) .
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| Illustration 22 | g03872055 |
- Install Tooling (N) .
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| Illustration 23 | g02629016 |
- Connect hose assembly (3) from the pump supply to Tooling (J) .
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| Illustration 24 | g02629019 |
- Connect hose assembly (4) from Tooling (K) to the No. 1 flow meter inlet.
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| Illustration 25 | g02629058 |
Transmission Oil Pump | |
- Connect hose assembly (5) from the outlet of the No. 1 flow meter to Tooling (L) .
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| Illustration 26 | g02629076 |
Main Relief Valve And Clutch Supply Rail | |
- Connect hose assembly (6) from Tooling (U) to the No. 2 flow meter inlet.
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| Illustration 27 | g03872108 |
Converter Outlet | |
- Connect hose assembly (7) from the outlet of the No. 2 flow meter to Tooling (N) .
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| Illustration 28 | g02629098 |
Transmission Lubrication Oil | |
- Connect lube line (8) from the test bench to Tooling (D). Maintain an oil pressure of 275 kPa (40 psi).
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| Illustration 29 | g02629117 |
- Connect a pressure gauge to pressure tap (9) and (10) .
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| Illustration 30 | g02629137 |
(9) Transmission Oil Pump (10) Converter Inlet Oil Pressure | |
- Connect a pressure gauge to pressure tap (11) and (12) .
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| Illustration 31 | g02629142 |
(11) Torque Converter Outlet Pressure Tap (12) Transmission Lubrication Pressure Tap | |
- Connect six pressure gauges to pressure taps (13), (14), (15), (16), (17), and (18) .
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| Illustration 32 | g02629156 |
(13) No. 6 clutch (14) No. 5 clutch (15) No. 4 clutch (16) No. 3 clutch (17) No. 2 clutch (18) No. 1 clutch | |
- Connect Tooling (P) to six clutch solenoids.
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| Illustration 33 | g02629157 |
- Connect Tooling (P) to Tooling (P) .
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| Illustration 34 | g02641017 |
- Connect Tooling (P) to a power source. Refer to Tool Operating Manual, NEHS0644 or Tool Operating Manual, NEHS0996 for the correct operating instructions.
Note: Make sure that the transmission is secured to the test bench. Tighten all bolts to the proper torque.
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| Illustration 35 | g00877510 |
Tooling (P) | |
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| Illustration 36 | g01457869 |
Tooling (P) | |
Test Procedure
TA3 Navigation
- Select "Wheel Loaders".
- Select "950K-24V" or "962K-24V".
Harness Test (TA3 only)
- Make sure that the harness is properly connected.
- Use Tooling (P) to perform the harness test.
- Record the values in Table 6.
Note: Do not continue testing until Harness Test passes.
Solenoid Test (TA2 only)
- Make sure that the harness is properly connected.
- Use Tooling (P) to perform the solenoid test.
- Record the values in Table 6.
Note: Do not continue testing until Solenoid Test passes.
Start Checks
- 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.
Note: Refer to Testing and Adjusting, KENR5791, "950K and 962K Wheel Loader Power Train" for the correct adjusting procedures.
- With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 965 ± 10 rpm.
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| Illustration 37 | g02720621 |
- The input flow should be 53 ± 4 L/min (14 ± 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.
- Shift the transmission through all directions and through all speed ranges to eliminate air from the transmission controls.
- Confirm the correct clutch engagement with Table 4.
Show/hide table
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
- The lube pressure must be within 14 kPa (2 psi) of the average lube pressure of the transmissions tested. (Maximum 138 kPa (20 psi) Minimum 69 kPa (10 psi).
Note: If there is no lube pressure after 3 seconds, stop input rotation and check connections on test bench and transmission.
- Record the values in Table 7.
- Adjust the input speed to 2200 ± 10 rpm.
- Refer to Table 8 for the correct supply pressure. Adjust the transmission hydraulic control relief valve, if necessary.
- The correct lube pressure for FORWARD 2 is 338 kPa (49 psi). The correct lube pressure for all other gear ranges is 365 kPa (53 psi).
- Adjust the transmission hydraulic control relief valve, if necessary.
- Record the value in Table 7.
Torque Converter Inlet Pressure
- Adjust the input speed to 965 ± 10 rpm.
- Shift the transmission to FORWARD 1.
- Use Tooling (U) to block momentarily the flow at the converter outlet.
- The converter inlet pressure must be 1007 ± 55 kPa (146 ± 8 psi).
- Open the lube flow.
- Record the value in Table 11.
Clutch Leakage Check
- Adjust the input rotation to 965 ± 45 rpm.
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.
- Shift the transmission to the FORWARD 1 position.
- Adjust the input rotation to 1700 ± 10 rpm.
- Record the input flow in Table 12.
- Record the lube flow in Table 12.
- The leakage is obtained by subtracting the lube flow from the input flow.
- Record the calculation in Table 12.
- Adjust the input rotation to 965 ± 45 rpm.
- 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.
- The leakage in each gear must be within ±3 L/min (0.8 US gpm) of the average of transmissions tested.
- The leakage difference between FIRST, THIRD, and FOURTH gears or between FORWARD and REVERSE should not exceed 2.3 L/min (0.6 US gpm).
- The leakage difference between SECOND gear and all other gears must not exceed 3 L/min (0.8 US gpm) of the average difference of the transmissions tested (Maximum 3.8 ± 3 L/min (1.0 ± 0.8 US gpm)).
Lube Circuit Check
- Adjust the input rotation until the lube flow is 76 ± 4 L/min (20 ± 1 US gpm). Maintain this flow during this check.
- Shift the transmission to FORWARD 3.
- The lube pressure must be between 140 ± 14 kPa maximum (20 ± 2 psi) and 69 kPa (10 psi) minimum.
- Record the value in Table 13.
Speed Sensor Test
- Adjust the Input Flow to 53 ± 4 L/min (14 ± 1 US gpm).
Note: This transmission arrangement has two output speed sensors that must be tested.
- Adjust the Input Rotation to 695 rpm.
- Shift the transmission to FORWARD 2.
- Use Tooling (Q) to measure the sensor signal voltage. Measure each output speed sensor.
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| Illustration 38 | g03872260 |
- Verify that both output speed sensors continue to have output.
- Record the values in Table 10.
- Verify the values with Table 9.
Contamination Control
- Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.
- Record the results in Table 14.
- Remove the transmission from the test bench if the test bench oil supply is within specifications.
Transmission Bench Test Data Sheet
| CATERPILLAR | Transmission Bench Test Data Sheet | Test Date:_______ |
| Model:_______ | ||
| Work Order:_______ | Serial No.:_______ | |
Solenoid Test
| Solenoid Test | Solenoid 1 | Solenoid 2 | Solenoid 3 | Solenoid 4 | Solenoid 5 | Solenoid 6 |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
Start Checks
| Lube Pressure | Input Speed (960 ± 45 rpm) | _______kPa _______(psi) |
Supply Pressure | Input Speed (2200 ± 80 rpm) | _______kPa _______(psi) |
||
| Supply Pressure | |
| Machine Model | Pressure |
| 950K, 962K | 2760 ± 70 kPa (400 ± 10 psi) |
Speed Sensor Test
| Sensor | Minimum Voltage (VRMS) |
| Output Speed Sensor 1 | 23±12 |
| Output Speed Sensor 2 | 23±12 |
| Speed Sensor Test | Input Flow 53 ± 4 L/min (14 ± 1 US gpm) Input Rotation 695 rpm |
|
| Sensor | Gear Range | |
| FORWARD 1 | FORWARD 2 | |
| Output Speed Sensor 1 | _____________VRMS | ______________VRMS |
| Output Speed Sensor 2 | ______________VRMS | ______________VRMS |
Torque Converter Inlet Pressure
| Torque Converter Inlet Pressure | Input Speed (965 ± 45 rpm) | _______kPa _______(psi) |
||
Clutch Leakage Check
| Clutch Leakage Check | Input Speed (1700 ± 30 rpm) Approximate Input Flow 136 ± 4 L/min (36 ± 1 US gpm) |
||||||||
| Gear Range | 1F | 2F | 3F | 4F | 1R | 2R | 3R | 4R | N |
Input Flow |
______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ |
Lube Flow |
______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ |
Leakage |
______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ |
Lube Circuit Check
| Lube Circuit Check | Gear Range FORWARD 3 Lube Flow 76 ± 4 L/min (20 ± 1 US gpm) |
||
| Input Rotation | _______rpm |
Lube Pressure | _______kPa _______(psi) |
ISO Particle Count
| ISO Particle Count | Sample the test bench oil supply. |
________/________Particle Count |
| ______________________________________ Technician |
______________________________________ Supervisor |