Bench Test Procedure for a 986H Wheel Loader Transmission {3030, 3073} Caterpillar

Wheel Loader

986H (S/N: 9861-UP)

Introduction

© 2016 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 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

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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 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	g03479480

1. Install Tooling (A) to the test stand.
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2. Use a hoist to install the transmission on to Tooling (A). The weight of the transmission is 1814 kg (4000 lb).
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3. Install Tooling (B) to the input end of the transmission.
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4. Use a hoist to install Tooling (C) to the input end of the transmission.
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   Illustration 7	g03479593

5. Use a hoist to install Tooling (D) onto Tooling (C).
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   Illustration 8	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 9	g03479682

7. Install Tooling (E) onto Tooling (D).
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   Illustration 10	g03479696

8. Install Tooling (F) onto Tooling (E).
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9. Align the transmission with the input drive shaft.

10. Connect the input drive shaft with Tooling (F).
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    Illustration 12	g03374951

11. Close and latch the drive shaft guard.
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    Illustration 13	g03375318

12. Tighten all four castle nuts and jack bolts on the test bench bed.
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    Illustration 14	g03479736

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    Illustration 15	g03479758

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

    Note: On output end of the transmission, route chains through lifting links to prevent slippage during testing. Refer to Illustration 14.

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    Illustration 16	g03480141
    Torque Converter (in)

14. Install Tooling (J) to the transmission.
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    Illustration 17	g03480179
    Controls (in)

15. Install Tooling (K) to the transmission.
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    Illustration 18	g03480217
    Torque Converter (out)

16. Install Tooling (L) to the transmission.
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    Torque Converter (out)

17. Install Tooling (M) to the transmission.
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    Illustration 20	g03480324
    Torque Converter (out)

18. Install Tooling (N) onto Tooling (M).
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    Illustration 21	g03480437
    Lube (in)

19. Install Tooling (P) to the transmission.
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    Illustration 22	g03488340
    Main pump supply

20. Connect Hose Assembly (1) from Flowmeter 2 (out) to Tooling (Q).
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    Illustration 23	g03480541

21. Connect Hose Assembly (2) from Tooling (Q) to Flowmeter 1 (in).
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    Illustration 24	g03480496
    Controls (in)

22. Connect Hose Assembly (3) from Flowmeter 1 (out) to Tooling (K).
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    Illustration 25	g03480556

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    Illustration 26	g03480616

23. Connect Hose Assembly (4) from Tooling (Q) to Tooling (R).
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    Illustration 27	g03480676

24. Connect Hose Assembly (5) from Tooling (R) to Flowmeter 3 (in).
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    Illustration 28	g03483161
    Torque Converter (in)

25. Connect Hose Assembly (6) from Flowmeter 3 (out) to Tooling (J).
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    Torque Converter (out)

26. Connect Hose Assembly (7) from Tooling (N) to Flowmeter 4 (in).
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    Lube (in)

27. Connect Hose Assembly (8) from Flowmeter 4 (out) to Tooling (P).
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    Illustration 31	g03483289
    Spindle Lube

28. Connect Hose Assembly (9) to Tooling (D)
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    Illustration 32	g03483641
    3447 kPa (500 psi) (10) Clutch No. 1 (11) Clutch No. 2 (12) Clutch No. 3 (13) Clutch No. 4 (14) Clutch No. 5 (15) Clutch No. 6

29. Connect pressure gauges to pressure taps (10-15).
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    Illustration 33	g03483959
    Lockup Clutch 3447 kPa (500 psi)

30. Connect a pressure gauge to pressure tap (16).
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    Illustration 34	g03483985
    Controls (in) 3447 kPa (500 psi)

31. Connect a pressure gauge to pressure tap (17).
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    Illustration 35	g03483995
    Torque Converter (in) 3447 kPa (500 psi)

32. Connect a pressure gauge to pressure tap (18).
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    Illustration 36	g03484002
    Torque Converter (out) 3447 kPa (500 psi)

33. Connect a pressure gauge to pressure tap (19).
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    Illustration 37	g03484017
    Lube (in) 345 kPa (50 psi)

34. Connect a pressure gauge to pressure tap (20).
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    Illustration 38	g03484081

35. Install Tooling (S) to the transmission.
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    Illustration 39	g03484085

36. Connect Tooling (S) to Tooling (T).

Test Procedure

Harness Test

1. Make sure Tooling (S) is properly connected.

2. Use Tooling (T) to perform the solenoid test.

3. Record the values in Table 6.

   Note: Do not continue testing until Harness Test passes.

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.

2. Set the input flow to 91 ± 8 L/min (24 ± 2 US gpm). The pump supply pressure should be minimum 1724 kPa (250 psi).
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   Illustration 40	g02720621

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 800 ± 20 rpm.

4. Adjust Tooling (R) until a split flow of 45 ± 8 L/min (12 ± 2 US gpm) for controls and 45 ± 8 L/min (12 ± 2 US gpm) for TC (in) is achieved.

5. 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.

6. Shift the transmission through all gear ranges until air is eliminated to stabilize pressures and flows.

7. Verify the correct clutch engagement. Refer to Table 4.
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   Table 4

   Clutch Engagement Checks
   Gear	1F	2F	3F	4F	1R	2R	3R	4R
   Clutch 1					X	X	X	X
   Clutch 2	X	X	X	X
   Clutch 3				X				X
   Clutch 4			X				X
   Clutch 5		X				X
   Clutch 6	X				X

8. With the transmission in NEUTRAL position, measure Lube flow, and Lube, Controls, TC (in), and TC (out) pressures.

9. Record the values in Table 8.

10. Confirm the values with 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.

11. With the transmission in NEUTRAL, adjust the input flow to 174 ± 8 L/min (46 ± 2 US gpm).

12. Adjust the input rotation to 1800 ± 20 rpm.

13. Adjust Tooling (R) until a split flow of 98 ± 7.6 L/min (26 ± 2 US gpm) for controls and 76 ± 7.6 L/min (20 ± 2 US gpm) for TC (in) is achieved.

14. Wait until flows and pressures stabilize.

15. Repeat Steps 8 through 10.

Torque Converter Block Check

1. Set the input flow to 91 ± 8 L/min (24 ± 2 US gpm).

2. Adjust the input speed to 800 ± 20 rpm.

3. Adjust Tooling (R) until a split flow of 45 ± 8 L/min (12 ± 2 US gpm) for controls and 45 ± 8 L/min (12 ± 2 US gpm) for TC (in) 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 841 kPa (122 psi) and 1020 kPa (148 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 182 ± 8 L/min (48 ± 2 US gpm).

2. Shift into FORWARD 3 and set the input speed to 1800 ± 20 rpm.

3. Adjust Tooling (R) until a split flow of 98 ± 8 L/min (26 ± 2 US gpm) for controls and 76 ± 8 L/min (20 ± 2 US gpm) for TC (in) is achieved.

4. Lube pressure must be between 138 kPa (20 psi) and 241 kPa (35 psi).

5. Record the value in Table 10.

Low Idle Pressure Checks

1. Set the input flow to 91 ± 8 L/min (24 ± 2 US gpm).

2. Adjust the input rotation to 800 ± 20 rpm.

3. Adjust Tooling (R) until a split flow of 45 ± 8 L/min (12 ± 2 US gpm) for controls and 45 ± 8 L/min (12 ± 2 US gpm) for TC (in) is achieved.

4. Shift the transmission to FORWARD 1.

5. Record Lube Flow, Controls, TC (in), TC (out), and Lube pressures, and Horse Power Loss in Table 12.

6. Confirm values with Table 11.

7. Record all Clutch pressures in Table 14.

8. Confirm values with Table 13.

9. Shift transmission through FORWARD 2, FORWARD 3, FORWARD 4, REVERSE 4, REVERSE 3, REVERSE 2, and REVERSE 1.

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

10. Repeat Steps 5 through 8.

High Idle Pressure Checks

1. Set the input flow to 174 ± 8 L/min (46 ± 2 US gpm).

2. Adjust the input rotation to 800 ± 20 rpm.

3. Adjust Tooling (R) until a split flow of 98 ± 8 L/min (26 ± 2 US gpm) for controls and 76 ± 8 L/min (20 ± 2 US gpm) for TC (in) is achieved.

4. Shift the transmission to FORWARD 1 and increase input rotation to 1800 ± 20.

5. Record Lube Flow, Controls, TC (in), TC (out), and Lube pressures, and Horse Power Loss in Table 16.

6. Confirm values with Table 15.

7. Record all Clutch pressures in Table 18.

8. Confirm values with Table 17.

9. Shift transmission through FORWARD 2, FORWARD 3, FORWARD 4, REVERSE 4, REVERSE 3, REVERSE 2, and REVERSE 1.

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

10. Repeat Steps 2 through 8.

Speed Sensor Test

1. Set the input flow to 91 ± 7.6 L/min (24 ± 2 US gpm).

2. Set the input rotation to 800 ± 20 rpm.

3. Adjust Tooling (R) until a split flow of 45 ± 7.6 L/min (12 ± 2 US gpm) for controls and 45 ± 7.6 L/min (12 ± 2 US gpm) for TC (in) is achieved.

4. Shift the transmission to FORWARD 2.

5. Record Output Speed 1 and Output Speed 2 in Table 19.

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 20.

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

Low Idle Pressure Checks

High Idle Pressure Checks

Speed Sensor Test

ISO Particle Count