Bench Test Procedure for 966L, 966M, 972L, and 972M Wheel Loader Transmission {3030, 3066, 3073, 3101} Caterpillar

Wheel Loader

966L (S/N: FSL1-UP; FRS1-UP)

966M (S/N: MD71-UP; EJA1-UP; DYC1-UP; R8D1-UP; LMM1-UP; KJP1-UP)

972L (S/N: RFB1-UP)

972M (S/N: L8E1-UP; LSJ1-UP; GGN1-UP; WGN1-UP; A8P1-UP; JPR1-UP; M8W1-UP)

Introduction

© 2018 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 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

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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 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.

Illustration 3	g02139237

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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. These tools are suggested and may very depending on availability and bench configuration.

Installation Procedure

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1. Install Tooling (A) to the test bench as shown

   Note: Install 440-5341 Spacers between 4C-9998 Bracket and 9U-6001 Crossmember.

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2. Use a hoist to install the transmission on to Tooling A. The weight of the transmission is 1000 kg (2204 lb)
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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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   Illustration 8	g03374636

5. Install Tooling (D) on Tooling (C).
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   Illustration 9	g03374665

6. Adjust and tighten the collet on Tooling (D)

   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 10	g03374699

7. Install Tooling (E) to the input shaft of Tooling (D).
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   Illustration 11	g03374903

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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    Illustration 13	g03374951

11. Install the drive shaft guard.
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12. Tighten all four jack bolts and all four castle nuts on test bench bed.
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    Illustration 16	g03375125

13. Install Tooling (H) to both ends of the transmission.

    Note: On input end of the transmission, route chain through the lift eye to prevent slippage.

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    Illustration 17	g03375663

14. Remove cover and magnetic filter.

    Note: Magnetic filter is not shown in the illustration.

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    Illustration 18	g03377529

15. Install Tooling (J) to pump mount opening.
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    Illustration 19	g03377339

16. Install Tooling (K) to sump opening.
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    Illustration 20	g03377277
    Controls (in)

17. Install Tooling (L) to the transmission.
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    Lube (in)

18. Install Tooling (L) to the transmission.
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    Illustration 22	g03377786
    TC (out)

19. Install Tooling (M) to the transmission.
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    Illustration 23	g03377854

20. Connect Tooling (N) to Tooling (M).
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    Illustration 24	g03378031

21. Install necessary fittings (1) to Tooling (P) and (Q).
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    Illustration 25	g03384351
    (2) Spindle Drive Adapter Lube

22. Connect Hose Assembly (2) to Tooling (D).
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    Illustration 26	g03424954

23. Connect Tooling (Q) to Tooling (P) (in).
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    Illustration 27	g03378382
    (3) Main Pump Supply

24. Connect hose assembly (3) from pressurized flowmeter (out) to Tooling (Q).
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    Illustration 28	g03384500

25. Connect Hose Assembly (4) from Tooling (Q) to Flowmeter 2 (in).
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    (5) Controls (in)

26. Connect Hose Assembly (5) from Flowmeter 2 (out) to Tooling (L).
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    Illustration 30	g03384681

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    Illustration 31	g03384095
    (6) Torque Converter (in)

27. Connect Hose Assembly (6) from Tooling (P) to Torque Converter (in).
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    Illustration 32	g03384458
    (7) Torque Converter (out)

28. Connect Hose Assembly (7) from Tooling (N) to Flowmeter 3 (in).
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    (8) Lube (in)

29. Connect Hose Assemble (8) from Flowmeter 3(out) (L) to Tooling.
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    Illustration 34	g03384699
    3447 kPa (500 psi) (9) Clutch No. 6 (10) Clutch No. 5 (11) Clutch No. 4 (12) Clutch No. 3 (13) Clutch No. 2 (14) Clutch No. 1

30. Connect pressure gauges to pressure taps (9-14).
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    Illustration 35	g03385084
    1379 kPa (200 psi) (15) Torque Converter (In)

31. Connect a pressure gauge to pressure tap (15).
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    Illustration 36	g03385094
    345 kPa (50 psi) (16) Lube (In)

32. Connect a pressure gauge to pressure tap (16).
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    Illustration 37	g03385117
    (17) High Pressure supply 3447 kPa (500 psi) (18) Low Pressure supply 1379 kPa (200 psi) (19) Torque Converter (in) 1379 kPa (200 psi)

33. Connect pressure gauges to pressure taps (17-19).
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    Illustration 38	g03385124
    3447 kPa (500 psi) (20) Lube (In)

34. Connect a pressure gauge to pressure tap (20).
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    Illustration 39	g03385133

35. Install Tooling (R) to the transmission.
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    Illustration 40	g03385148

36. Install Tooling (R) to Tooling (S).

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

Test Procedure

TA3 Navigation

1. Select “Wheel Loaders”.

2. Select “966M-24V" or "972M-24V”.

Harness Test

1. Make sure that Tooling (R) is properly connected.

2. Use Tooling (S) to perform the harness test.

3. Record the values in Table 6.

   Note: Do not continue testing until harness test passes.

Start Checks

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 during the test.

2. Set the input flow to 56.8 ± 7 L/min (15 ± 1.5 US gpm). The pump supply pressure should be minimum 2772 ± 103 kPa (402 ± 15 psi)
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   Illustration 41	g02720621

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 965 rpm.

4. Adjust Tooling (P) until a split flow of 34 ± 6 L/min (9 ± 2 US gpm) for Controls and 23 ± 6 L/min (6 ± 2 US gpm) for TC inlet flow is achieved.

5. Shift the transmission through all gear selections until air is eliminated to stabilize the pressures/flows.

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

   Note: If there is no lube pressure after 30 seconds, stop the test and verify test stand and transmission connections.

7. Verify that the active clutches are correct for each gear range. Refer to Table 4.

8. Stop the input rotation.
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   Table 4

   Transmission Clutch Assignments
   Operation	Clutches
   	1	2	3	4	5	6
   Neutral			X
   Forward 1		X				X
   Forward 2		X			X
   Forward 3		X		X
   Forward 4		X	X
   Reverse 1	X					X
   REVERSE 2	X				X
   REVERSE 3	X			X
   REVERSE 4	X		X

9. With the transmission in NEUTRAL position, measure Lube, Controls, and TC inlet flows, and Lube, Controls, TC inlet, and TC out pressures.

10. Record the pressures and flows in Table 8.

11. Confirm that pressures and flows are within the reference values in Table 7.

    Note: If the values do meet acceptance criteria, stop the test and verify test stand, instrumentation hook-ups, calibration, and/or repair/adjust the transmission.

12. For warm-up in high idle, put the transmission in NEUTRAL position.

13. Adjust input flow to 114 ± 4 L/min (30 ± 1 US gpm).

14. Set input speed to 2000 rpm.

15. Adjust Tooling (P) until a split flow of 72 ± 6 L/min (19 ± 2 US gpm) for Controls and 42 ± 6 L/min (11 ± 2 US gpm) for TC inlet is achieved.

16. Wait until flows and pressures stabilize.

17. Repeat Steps 9 and 11.

Torque Converter Block Check

1. Set the input flow to 57 ± 7 L/min (15 ± 2 US gpm).

2. Adjust the input speed to 965 ± 10 rpm.

3. Adjust Tooling (P) until a split flow of 34 ± 6 L/min (9 ± 2 US gpm) for Controls and 23 ± 6 L/min (6 ± 2 US gpm) for TC inlet flow is achieved.

4. Shift the transmission to FORWARD 1.

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

6. The converter inlet and outlet pressures must be between 860 kPa (125 psi) and 1140 kPa (165 psi).

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

7. Open the lube flow.

8. Record the value in Table 9.

Lube Circuit Check

1. Set the input flow to 114 L/min (30 US gpm).

2. Shift into FORWARD 3 and set the input speed to 2000 rpm.

3. Adjust Tooling (P) until a split flow of 72 ± 6 L/min (19 ± 2 US gpm) for Controls and 42 ± 6 L/min (11 ± 2 US gpm) for TC inlet is achieved.

4. Lube pressure must be between 55 kPa (8 psi) and 117 kPa (17 psi).

5. Record the value in Table 10.

eMRV Check

1. Set the input flow to 114 L/min (30 US gpm) at 2758 kPa (400 psi).

2. Adjust the input rotation to 2000 rpm.

3. Adjust Tooling (P) until a split flow of 72 ± 6 L/min (19 ± 2US gpm) for Controls and 42 ± 6 L/min (11 ± 2 US gpm) for TC inlet is achieved.

4. Select the tab marked "eMRV High Current/Low Pressure" on the test screen.

   Note: Do not exceed 10 seconds at this setting.

5. Record Controls pressure in Table 11.

6. Select the tab marked "eMRV Low Current/High Pressure" on the test screen.

7. Record Controls pressure in Table 11.

8. Confirm values with Table 11.

Low Idle Check

1. Set the input flow to 57 L/min (15 US gpm) at 2689 kPa (390 psi).

2. Adjust the input rotation to 965 rpm.

3. Adjust Tooling (P) until a split flow of 34 ± 6 L/min (9 ± 2 US gpm) for Controls and 23 ± 6 L/min (6 ± 2 US gpm) for TC inlet flow is achieved.

4. Shift the transmission to the FORWARD 1 position.

5. Measure Lube, Controls. TC inlet and TC outlet pressures.

6. Measure Lube, Controls, and TC inlet flows.

7. Record the input pressures and flows in Table 14.

8. Confirm the input pressures and flows with Table 12.

9. Record clutch pressures in Table 15.

10. Confirm clutch pressures with Table 13.

11. Shift the transmission through positions FORWARD 2, FORWARD 3, FORWARD 4, REVERSE 1, REVERSE 2, REVERSE 3, REVERSE 4, and NEUTRAL.

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

12. Repeat Steps 2 through 11 for each gear range.

High Idle Check

1. Set the input flow to 114 L/min (30 US gpm) at 2758 kPa (400 psi).

2. Adjust the input rotation to 965 rpm.

3. Shift the transmission to FORWARD 1 and increase the input rotation to 2000 rpm.

4. Adjust Tooling (P) until a split flow of 72 ± 6 L/min (19 ± 2US gpm) for Controls and 42 ± 6 L/min (11 ± 2 US gpm) for TC inlet is achieved.

5. Measure the Lube, Control, TC inlet, and TC outlet pressures.

6. Measure Lube, Controls, and TC inlet flows.

7. Record the input pressures and flows in Table 18.

8. Confirm the input pressures and flows with Table 16.

9. Record clutch pressures in Table 19.

10. Confirm clutch pressures with Table 17.

11. Adjust the input rotation to 965 rpm.

12. Shift the transmission through positions FORWARD 2, FORWARD 3, FORWARD 4, REVERSE 1, REVERSE 2, REVERSE 3, REVERSE 4, and NEUTRAL

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

13. Repeat Steps 3 through 12 for each gear range.

Speed Sensor Test

1. Set the input flow to 57 L/min (15 US gpm).

2. Adjust input rotation to 965 rpm.

3. Adjust Tooling (P) until a split flow of 34 ± 6 L/min (9 ± 2 US gpm) for Controls and 23 ± 6 L/min (6 ± 2 US gpm) for TC inlet flow is achieved.

4. Shift the transmission to FORWARD 2.

5. Document Speed Sensors 1 and 2 in Table 20.

6. Stop rotation.

7. Shift the transmission to NEUTRAL.

8. Disconnect Speed Sensors 1 and 2 and connect Speed Sensor 3.

9. Adjust rotation to 965 rpm.

10. Shift the transmission to FORWARD 2.

11. Document Speed Sensor 3 in Table 20.

12. Compare speeds with given speeds listed in Table 20.

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 21.

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

Transmission Bench Test Data Sheet

Harness Test

Start Checks

Torque Converter Block Check

Lube Circuit Check

eMRV Check

Low Idle Check

High Idle Check

Speed Sensor Test

Contamination Control