Bench Test Procedure for a 950H, 962H, 966G, 966G Series 2, 966H, 972G, 972G Series 2, and 972H Wheel Loader Transmission and a R1600H Load Haul Dump {3030, 3066, 3073, 3101} Caterpillar

Load Haul Dump

R1600H (S/N: 9SD1-UP)

Wheel Loader

950H (S/N: N1A1-UP; JAD1-UP; M1G1-UP; J5J1-UP; K5K1-UP; MXL1-UP; JLX1-UP)

962H (S/N: N4A1-UP; SSA1-UP; M3G1-UP; J6J1-UP; K6K1-UP; MAL1-UP; L5S1-UP; PCW1-UP)

966G (S/N: AAH1-UP; HDH1-UP; 3ZS1-UP; 9RS1-UP; 3PW1-UP; 3SW1-UP; 8XW1-UP)

966G Series II (S/N: AXJ1-UP; AXL1-UP; ANT1-UP; AWY1-UP; ANZ1-UP; AWZ1-UP)

966H (S/N: BJ61-UP; BS61-UP; A6D1-UP; RYF1-UP; A6G1-UP; A6J1-UP; TAL1-UP; FMW1-UP)

972G (S/N: 7LS1-UP; AAW1-UP; 1EW1-UP; 4WW1-UP; 6AW1-UP; 9GW1-UP)

972G Series II (S/N: AXC1-UP; AXE1-UP; AXN1-UP; AWP1-UP; AXP1-UP; ANY1-UP)

972H (S/N: GTA1-UP; LCC1-UP; A7D1-UP; NPE1-UP; A7G1-UP; A7J1-UP; WXZ1-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 questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. To address an urgent issue, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

• Knowledge Network

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 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 additional filtering can affect pressure. The required tools that are listed in Table 3 were used to develop this test procedure. For additional information about tooling, consult Caterpillar Service Technology Group (800) 542-8665.

Installation Procedure

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Illustration 3	g03804002

1. Install Tooling (A) to the output end of the transmission.
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   Illustration 4	g00993298

2. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1180 kg (2600 lb).
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   Illustration 5	g00993300

3. Install Tooling (B) on the torque converter.
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   Illustration 6	g00993301

4. Install Tooling (C) to the transmission case.
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   Illustration 7	g00993302

5. Install Tooling (D) on Tooling (C).
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   Illustration 8	g00993303

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

   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	g00993304

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).

9. Use hoist and pry bars to slide the transmission forward to align with input drive shaft.
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   Illustration 11	g00993306

10. Connect the input drive shaft to Tooling (F).
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    Illustration 12	g00993307

11. Install the drive shaft guard.
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    Illustration 13	g03802221

12. Tighten all four castle nuts and jack bolts on the test stand.
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    Illustration 14	g00993308

13. Install Tooling (H) to the output end of the transmission.
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    Illustration 15	g00993309

14. Install Tooling (H) to the input end of the transmission.
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    Illustration 16	g00993310

15. Remove two covers (1).
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    Illustration 17	g00993311

16. Remove magnetic filter (2).
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    Illustration 18	g06037942

17. Install Tooling (J). Orient the slot.
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    Illustration 19	g06037950
    Gravity Feed Oil Supply

18. Install Tooling (K).
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    Illustration 20	g06037964
    Cover (Oil Pump)

19. Install Tooling (L).
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    Illustration 21	g06037967
    Outlet for the Transmission Oil Pump

20. Install Tooling (M).
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    Illustration 22	g06037972
    Controls (in)

21. Install Tooling (N).
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    Illustration 23	g06037975
    Torque Converter (out)

22. Install Tooling (P).
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    Illustration 24	g06037981
    Torque Converter (out)

23. Connect Tooling (Q) to Tooling (P).
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    Illustration 25	g06037994
    Lube (in)

24. Install Tooling (R).
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    Illustration 26	g06038002
    Gravity Feed Oil Supply

25. Connect hose assembly (3) from the pump supply to Tooling (K).
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    Illustration 27	g06038008
    Outlet for the Transmission Oil Pump

26. Connect hose assembly (4) from Tooling (M) to the No. 1 flow meter inlet.
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    Illustration 28	g06038011
    Controls (in)

27. Connect hose assembly (5) from the No. 1 flow meter outlet to Tooling (N).
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    Illustration 29	g06038015
    Torque Converter (out)

28. Connect hose assembly (6) from Tooling (Q) to the No. 2 flow meter inlet.
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    Illustration 30	g06038019
    Lube (in)

29. Connect hose assembly (7) from the No. 2 flow meter outlet to Tooling (R).
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    Illustration 31	g00993324
    Spindle Lube

30. 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 32	g00993325
    Pump Pressure

31. Connect a pressure gauge to pressure tap (9).
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    Illustration 33	g00993326
    Torque Converter (in) Pressure

32. Connect a pressure gauge to pressure tap (10).
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    Illustration 34	g00993327
    Torque Converter (out) Pressure

33. Connect a pressure gauge to pressure tap (11).
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    Illustration 35	g00993328
    Lube Pressure

34. Connect a pressure gauge to pressure tap (12).
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    Illustration 36	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

35. Connect six pressure gauges to pressure taps (13), (14), (15), (16), (17), and (18).
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    Illustration 37	g00877510
    Tooling (S)

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    Illustration 38	g01457869
    Tooling (S)

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

Test Procedure

TA3 Navigation

1. Select “Wheel Loaders”.

2. Select “950H-24V”, “962H-24V”, “966G-24V”, “966H-24V”, or “972G-24V”.

Harness Test (TA3 Only)

1. Make sure that the harness is properly connected.

2. Use Tooling (S) to perform the solenoid 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 (S) 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, RENR2105, "966G Wheel Loader and 972G Wheel Loader Power Train" or Testing and Adjusting, RENR4387, "966G Series 2 Wheel Loader and 972G Series 2 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.

2. Open Gravity Feed and wait for transmission to fill to sump return port level.
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   Illustration 39	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. The input flow should be 57 ± 5 L/min (15 ± 1 US gpm).

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

5. Shift the transmission through all gears to eliminate air from the transmission controls. Verify 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 14 kPa (2 psi).

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

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

9. 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).

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

11. Record the values 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 (Q) to block momentarily the flow at the converter outlet.

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

4. The converter inlet pressure must be 1006 ± 48 kPa (146 ± 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 11.

5. Record the lube flow in Table 11.

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

7. Record the calculation in Table 11.

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 return to NEUTRAL when shifting between FORWARD and 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

Note: Per Service Magazine, SEPD1521, "A New Bearing is used in Planetary Transmission". There was a change in the bearings in the rebuild kit. Due to the bearing not being canceled or replaced, there are two options for lube pressure. Pressure will change depending on which bearing is used.

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:

   1. Shielded bearing pressure: 132 ± 14 kPa (19 ± 2 psi)

   2. Unshielded bearing pressure: 48 ± 21 kPa (7 ± 3 psi)

4. Record the value in Table 13.

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 40	g06038045
Tooling (T)

1. Connect Tooling (T) 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 (T) matches the value in Table 14.
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   Illustration 41	g00993349
   (25) Input Speed Sensor (26) Output Speed Sensor "No. 1" (27) Output Speed Sensor "No. 2"

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   Illustration 42	g00993353
   (28) Intermediate Speed Sensor "No. 1" (29) Intermediate Speed Sensor "No. 2"

5. Use Tooling (T) 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 14.

6. Record the values in Table 15.

7. Verify the test points with the values in Table 14.

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 16.

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

Transmission Bench Test Data Sheet

Solenoid/Harness Test

Start Checks

Torque Converter Inlet Pressure

Clutch Leakage Check

Lube Circuit Check

Speed Sensor Test

Contamination Control