Bench Test Procedure for a 950G, 950G Series 2, 962G, and 962G Series 2 Wheel Loader TransmissionIT62G and IT62G Series 2 Integrated Toolcarrier Transmission{3030, 3066, 3073, 3101} Caterpillar

Integrated Toolcarrier:

IT62G Series II (S/N: AYA1-UP)

IT62G (S/N: AKP1-UP; 6PS1-UP)

Wheel Loader:

950G Series II (S/N: BAA1-UP; AYB1-UP; AYD1-UP; AYL1-UP; AXR1-UP; AYS1-UP; AXX1-UP)

950G (S/N: 2JS1-UP; 4BS1-UP; 6NS1-UP; 3JW1-UP; 5FW1-UP; 5MW1-UP; 8JW1-UP)

962G Series II (S/N: BAB1-UP; BAC1-UP; BAD1-UP; AYE1-UP; AYG1-UP; AXS1-UP; AXY1-UP)

962G (S/N: BDP1-UP; 3BS1-UP; 5AS1-UP; 5RS1-UP; 4PW1-UP; 6EW1-UP; 6HW1-UP; 7BW1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS1468
02	Standardized
01	Added new introduction, Canceled Part Numbers section, and updated transmission arrangement.

© 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

Table 2

Machine Model	Transmission Arrangement
950G	114-8945, 157-0953, 176-0056, 176-0057, 177-8741, 186-2524, 186-2525, 186-2526, 186-2527
950G Series 2	190-3776, 190-3777, 191-2350, 191-2351, 199-2758, 214-9075
962G	141-2388, 157-0954, 176-0057, 177-8742, 186-2525, 186-2527
962G Series 2	190-3776, 190-3777, 191-2351, 191-2352, 214-9075
IT62G	141-2388, 157-0954, 177-8742, 186-2527
IT62G Series 2	191-2351

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 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.

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 used in order to compare values on portions of this transmission test. 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

Table 3

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
	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	439-3940	Link Bracket As	2
	6V-3822	Bolt (M10X1.5X35 mm)	2
	6V-5839	Washer	2
	1U-9722	Load Binder As (Ratchet Type)	3
S	1U-8301	Fitting	2
	9U-7444	Adapter (Flange)	2
	1P-4577	Half Flange	4
	8C-9024	Fitting As (Plain)	2
	6V-1820	Bolt (M10X1.5X30 mm)	8
	6V-5839	Washer	8
	6V-3965	Fitting As (Quick Disconnect)	2
	4J-0520	O-Ring Seal	2
	7M-8485	O-Ring Seal	2
	3J-1907	O-Ring Seal	2
J	1U-8304	Fitting (45 Degree)	2
	1U-8297	Adapter (Flange)	2
	1P-4577	Half Flange	4
	8C-9024	Fitting As (Plain)	2
	6V-1820	Bolt (M10X1.5X30 mm)	8
	6V-5839	Washer	8
	6V-3965	Fitting As (Quick Disconnect)	2
	4J-0520	O-Ring Seal	2
	7M-8485	O-Ring Seal	2
	3J-1907	O-Ring Seal	2
K	1U-9858	Flange (2 Bolt)	1
	5B-7666	Elbow	1
	6L-7349	Pipe Nipple	1
	5B-7660	Reducer Bushing	1
	3N-8699	Reducer Bushing	1
	1U-9879	Adapter (Quick Disconnect)	1
	6V-7673	Bolt (M12X1.75X50 mm)	2
	5P-8245	Hard Washer	2
L	8C-9024	Fitting As (Plain)	1
	8C-9025	Quick Coupler	1
	3B-7749	Fitting	1
	120-6843	Ball Valve	1
M	9U-7500	Transmission Analyzer Tool Gp	1
	OR
	277-2362	Transmission Analyzer III Gp	1
	9U-7498	Extension Cable	1
	9U-7495	Adapter Cable As (Wheel Loader)	1
N	9U-7400	Multitach Tool Gp	1
	211-1774	Adapter Cable As (Speed Sensor)	1
T	146-4080	Digital Multimeter	1
	5P-5677	Electrical Wire	1
	155-2270	Connecting Plug Kit	1
	186-3736	Connector Socket	2
P	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	7
	6V-4144	Coupler	7
Q	8T-0854	Pressure Gauge (0 to 1,000 kPa (0 to 145 psi))	2
	6V-4144	Coupler	2
R	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

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Illustration 3	g00935889

1. Use a hoist to install the transmission on the test bench. The weight of the transmission is 703 kg (1550 lb).

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Illustration 4	g03862937

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

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Illustration 5	g00935892

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

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Illustration 6	g00935895

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

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Illustration 7	g00935897

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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Illustration 8	g00935901

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

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Illustration 9	g00935902

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

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Illustration 10	g00935904

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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Illustration 11	g00935906

9. Align the transmission with the input drive shaft.

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

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Illustration 12	g00935908

11. Install the drive shaft guard.

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Illustration 13	g03802221

12. Tighten all four castle nuts and jack bolts.

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Illustration 14	g00935909

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Illustration 15	g00935910

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

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Illustration 16	g00935913

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

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Illustration 17	g03862605

15. Install Tooling (S) .

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Illustration 18	g00935915

16. Install Tooling (J) .

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Illustration 19	g00935917

17. Install Tooling (K) .

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Illustration 20	g00935921

18. Connect hose assembly (1) from the pump supply to Tooling (K) .

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Illustration 21	g03862630
Outlet for the Transmission Oil Pump

19. Connect hose assembly (2) from Tooling (S) to No. 1 flow meter inlet.

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Illustration 22	g03862940
Inlet For The Main Relief Valve And Clutch Supply Rail

20. Connect hose assembly (3) from the outlet of the No. 1 flow meter to Tooling (S) .

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Illustration 23	g00935925
Converter Outlet

21. Connect Tooling (L) to Tooling (J) .

22. Connect hose assembly (4) from Tooling (L) to No. 2 flow meter inlet.

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Illustration 24	g00935926
Inlet For The Transmission Lubrication Oil

23. Connect hose assembly (5) from the outlet of the No. 2 flow meter to Tooling (J) .

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Illustration 25	g00935933
Lubrication For The Spindle

24. Connect lube line (6) from the test bench to Tooling (D). Maintain an oil pressure of 275 kPa (40 psi).

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Illustration 26	g00935937
Transmission Lubrication Pressure Tap

Note: If you are using individual pressure gauges to measure the pressures, refer to Table 3 for the correct pressure gauges.

25. Connect a pressure gauge to pressure tap (7) .

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Illustration 27	g00935955
Torque Converter Outlet Pressure Tap

26. Connect a pressure gauge to pressure tap (8) .

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Illustration 28	g00935956
Pressure Tap For The Transmission Oil Pump

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

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Illustration 29	g00935958
Pressure Tap For The Converter Inlet Oil Pressure

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

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Illustration 30	g00935960

29. Connect six pressure gauges to pressure taps (11), (12), (13), (14), (15), and (16) .

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Illustration 31	g00935961
Cable connector (1-A) for No. 1 clutch solenoid (17) Cable connector (2-B) for No. 2 clutch solenoid (18) Cable connector (3-C) for No. 3 clutch solenoid (19) Cable connector (4-D) for No. 4 clutch solenoid (20) Cable connector (5-E) for No. 5 clutch solenoid (21) Cable connector (6-F) for No. 6 clutch solenoid (22)

30. Connect Tooling (M) to six clutch solenoids.

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Illustration 32	g00935962

31. Install Tooling (N) on the output yoke.

    Note: Make sure that the transmission is secured to the test bench. Tighten all bolts to the correct torque.

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Illustration 33	g00877510
Tooling (M)

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Illustration 34	g01457869
Tooling (M)

32. Connect Tooling (M) 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 "950G-24V", "962G-24V", or "IT62G-24V".

Harness Test (TA3 Only)

1. Make sure that the harness is properly connected.

2. Use Tooling (M) 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 (M) 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, SENR1380, "950G Wheel Loader, 962G Wheel Loader and IT62G Integrated Toolcarrier Power Train" or Testing and Adjusting, RENR4310, "950G Series II Wheel Loader, 962G Series II Wheel Loader and IT62 Series II 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.

2. Adjust the input flow to 53 ± 4 L/min (14 ± 1 US gpm).

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Illustration 35	g02720621

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 965 ± 45 rpm.

4. Shift the transmission through all directions and 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
   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. Each clutch should be engaged 12 times.

7. The lube pressure should be between 61 kPa (9 psi) and 113 kPa (16 psi).

8. Record the value in Table 8.

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

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

11. Record the value in Table 8.

Torque Converter Inlet Pressure Test

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

2. Shift the transmission to FORWARD 1.

3. Use Tooling (L) to block the lube flow momentarily.

4. The converter inlet pressure must be 960 ± 83 kPa (139 ± 12 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 97 L/min (26 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 5.7 L/min (1.5 US gpm) and 13.2 L/min (3.5 US gpm).

11. The leakage for FORWARD 2 and REVERSE 2 gear ranges should be between 8.3 L/min (2.2 US gpm) and 15.5 L/min (4.1 US gpm).

12. The difference of leakage between NEUTRAL, FIRST, THIRD, and FOURTH gear ranges should be within 3.8 L/min (1.0 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 must be 76 ± 14 kPa (11 ± 2 psi).

4. Record the value in Table 11.

Speed Sensor Test

Note: Older transmission arrangements will have five speed sensors that must be tested. There is one input speed sensor, two intermediate speed sensors, and two output speed sensors. Newer transmission arrangements have three individual speed sensors that must be tested. There is one input speed sensor and two output speed sensors. Identify each speed sensor.

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Illustration 36	g03862765
Tooling (T)

1. Connect Tooling (T) to input speed sensor (23) .

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

3. Shift the transmission to FORWARD 2.

4. Adjust the input rotation until the output speed that is measured at the output yoke is 240 ± 5 rpm.

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Illustration 37	g00946028
(23) Input Speed Sensor (24) Output Speed Sensor "No. 1" (25) Output Speed Sensor "No. 2" (26) Intermediate Speed Sensor "No. 1" (27) Intermediate Speed Sensor "No. 2"

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

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

Table 5

CATERPILLAR	Transmission Bench Test Data Sheet	Test Date:_______
		Model:_______
Work Order:_______		Serial No.:_______

Solenoid Test

Table 6

Solenoid Test	Solenoid 1	Solenoid 2	Solenoid 3	Solenoid 4	Solenoid 5	Solenoid 6
	_______ ohms	_______ ohms	_______ ohms	_______ ohms	_______ ohms	_______ ohms

Start Checks

Table 7

Supply Pressure
Machine Model	Pressure
950G, 962G, and IT62G	2897 ± 70 kPa (420 ± 10 psi)
950G Series 2, 962G Series 2, and IT62G Series 2	2723 ± 70 kPa (395 ± 10 psi)

Table 8

Lube Pressure

Input Speed (965 ± 45 rpm)

_______kPa _______(psi)

Supply Pressure

Input Speed (2200 ± 80 rpm)

_______kPa _______(psi)

Torque Converter Inlet Pressure Test

Table 9

Torque Converter Inlet Ratio Valve Pressure

Input Speed (965 ± 45 rpm)

_______kPa _______(psi)

Clutch Leakage Check

Table 10

Clutch Leakage Check		Input Speed (1700 ± 30 rpm) Approximate Input Flow 97 L/min (27 US gpm)
Gear Range	1F	2F	3F	4F	1R	2R	3R	4R	N
Input Flow	______	______	______	______	______	______	______	______	______
Lube Flow	______	______	______	______	______	______	______	______	______
Leakage	______	______	______	______	______	______	______	______	______

Lube Circuit Check

Table 11

Lube Circuit Check		Gear Range FORWARD 3 Lube Flow 76 ± 4 L/min (20 ± 1 US gpm)
Input Rotation	_______rpm	Lube Pressure	_______kPa _______(psi)

Speed Sensor Test

Table 12

Sensor	Minimum Voltage
	Volts (Vpp)	Volts (VRMS)
Input	19 Vpp	13 VRMS
Output Speed Sensor 1	11 Vpp	7 VRMS
Output Speed Sensor 2
Intermediate Speed Sensor 1
Intermediate Speed Sensor 2

Table 13

Speed Sensor Test	Output Speed (240 ± 5 rpm) Gear Range FORWARD 2
Input Speed Sensor	__________________ Volts/Vrms
Output Speed Sensor 1	__________________ Volts/Vrms
Output Speed Sensor 2	__________________ Volts/Vrms
Intermediate Speed Sensor 1	__________________ Volts/Vrms
Intermediate Speed Sensor 2	__________________ Volts/Vrms

ISO Particle Count

Table 14

ISO Particle Count

Sample the test bench oil supply.

________/________Particle Count

Table 15

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