- Integrated Toolcarrier:
- IT28G (S/N: 8CR1-3599; 9AR1-1060)
- Wheel Loader:
- 928G (S/N: 6XR1-3371; 7SR1-2035)
Introduction
| Revision | Summary of Changes in REHS1628 |
| 01 | Added new Introduction and Canceled Part Numbers section |
© 2012 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 special instruction contains the necessary information that is required to bench test-specific transmission arrangements. 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. This 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:
- Cat Dealer Techinical Communicator
- Dealer Solution Network
- Cat Technical Representative
- Knowledge Network
| Machine Model | Transmission Arrangement |
| 928G | 116-4860 |
| IT28G | 116-4860 |
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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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.
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 in order to develop this test procedure. For additional information about tooling, consult Caterpillar Service Technology Group (800) 542-8665.
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 1U-9585 | Mounting Block Gp | 1 |
| 1U-9584 | Rail As | 2 | |
| 1U-9586 | Swivel Head Support Gp | 1 | |
| FT-0703 | Support As. | 1 | |
| B | 1U-5798 | Drive Adapter Gp | 1 |
| C | 1U-6698 | Spindle Adapter | 1 |
| 4C-6174 | Adapter Ring (Hub) | 1 | |
| 0S-1588 | Bolt (3/8-16X1.25 inch) | 6 | |
| 5M-2894 | Hard Washer | 12 | |
| 2J-5245 | Bolt (3/8-16X1.25 inch) | 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) (1) | 1 |
| G | 1U-9359 | Drive Adapter (2) | 1 |
| H | 138-7573 | Link Bracket | 2 |
| 6V-8197 | Bolt (M12X1.75X40 mm) | 2 | |
| 6V-5839 | Washer | 2 | |
| 3B-4508 | Lockwasher | 2 | |
| 1U-9722 | Load Binder As (Ratchet Type) | 3 | |
| T | 1U-6234 | Adapter (Oil Supply) | 1 |
| 4F-7390 | O-Ring Seal | 1 | |
| J | 1U-6233 | Adapter As | 1 |
| 6V-3940 | Bolt (M8X1.25X25 mm) | 3 | |
| 9M-1974 | Hard Washer | 3 | |
| 5N-2918 | Fitting | 1 | |
| 5L-6669 | Reducer Bushing | 1 | |
| 1U-9879 | Adapter (Quick Disconnect) | 1 | |
| K | 1U-9871 | Flange | 1 |
| 4J-5267 | O-Ring Seal | 1 | |
| 8T-0271 | Bolt (M10X1.5X35 mm) | 4 | |
| 004-7270 | Pipe Fitting | 1 | |
| 6B-9081 | Reducing Bushing | 1 | |
| 7X-7646 | Fitting As | 1 | |
| L | 8C-9024 | Fitting As (Plain) | 1 |
| 5P-0492 | Adapter | 1 | |
| 7M-8485 | O-Ring Seal | 1 | |
| 7X-2470 | Adapter | 1 | |
| 2S-4078 | O-Ring Seal | 1 | |
| M | 8C-9024 | Fitting As (Plain) | 1 |
| 1U-9872 | Flange | 1 | |
| 4J-0519 | O-Ring Seal | 1 | |
| 8T-9515 | Bolt (M10X1.50X40 mm) | 4 | |
| N | 8C-9024 | Fitting As (Plain) | 1 |
| 8C-9025 | Quick Coupler | 1 | |
| 3B-7749 | Fitting | 1 | |
| 120-6843 | Ball Valve | 1 | |
| U | 8C-9024 | Fitting As (Plain) | 1 |
| 5P-0492 | Adapter | 1 | |
| 7M-8485 | O-Ring Seal | 1 | |
| P | 3T-0811 | O-Ring Adapter | 1 |
| 6V-3966 | Fitting As | 1 | |
| Q | 9U-7500 | Electronic Control Group | 1 |
| 9U-7498 | Extension Cable | 1 | |
| 9U-7497 | Adapter Cable As | 1 | |
| R | 8T-0862 | Pressure Gauge (-100 to 500 kPa (-15 to 72 psi)) | 1 |
| 6V-4144 | Coupler | 1 | |
| S | 8T-0855 | Pressure Gauge (0 to 4,000 kPa (0 to 580 psi)) | 3 |
| 6V-4144 | Coupler | 3 | |
| ( 1 ) | This drive adapter is used with the small drive shaft. |
| ( 2 ) | This drive adapter is used with the large drive shaft. |
Installation Procedure
- Install Tooling (A) on the test bench, as shown.
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| Illustration 1 | g00988581 |
- Use a hoist to install the transmission on the test bench. The weight of the transmission is 700 kg (1545 lb).
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| Illustration 2 | g00988582 |
- Install Tooling (B) on the torque converter.
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| Illustration 3 | g00988583 |
- Install Tooling (C) to the transmission case.
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| Illustration 4 | g00988585 |
- Install Tooling (D) on Tooling (C) .
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| Illustration 5 | g00988587 |
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) in order 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 6 | g00988590 |
- Install Tooling (E) to the input shaft of Tooling (D) .
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| Illustration 7 | g00988591 |
- 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 8 | g00988595 |
- Align the transmission with the input drive shaft.
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| Illustration 9 | g00988596 |
- Connect the input drive shaft to Tooling (F) .
- Install the drive shaft guard.
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| Illustration 10 | g00988597 |
- Install Tooling (H) to the output end of the transmission.
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| Illustration 11 | g00988599 |
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| Illustration 12 | g00988600 |
- Install Tooling (H) to the input end of the transmission.
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| Illustration 13 | g00988601 |
- Remove drain plug (1) .
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| Illustration 14 | g00988602 |
- Remove cover (2) .
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| Illustration 15 | g00988605 |
- Remove magnetic filter (3) .
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| Illustration 16 | g00988608 |
- Install Tooling (T). Orient the slot in an upward position, as shown.
Note: Tooling (T) will divert oil to the suction side of the transmission pump. Also, Tooling (T) will prevent oil from filling the oil pan.
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| Illustration 17 | g03127078 |
- Install Tooling (J) .
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| Illustration 18 | g00988613 |
- Install Tooling (K) .
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| Illustration 19 | g00988614 |
- Install Tooling (L) .
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| Illustration 20 | g00988616 |
- Install Tooling (M) .
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| Illustration 21 | g00988620 |
- Connect Tooling (N) to Tooling (M) .
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| Illustration 22 | g00988621 |
- Install Tooling (U) .
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| Illustration 23 | g03127083 |
- Install Tooling (P) .
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| Illustration 24 | g00988626 |
- Connect hose assembly (4) from the pump supply to Tooling (T) .
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| Illustration 25 | g03127090 |
- Connect hose assembly (5) from the No. 1 flow meter inlet to Tooling (K) .
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| Illustration 26 | g00988632 |
Outlet for the Transmission Oil Pump | |
- Connect hose assembly (6) from the outlet of the No. 1 flow meter to Tooling (L) .
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| Illustration 27 | g00988637 |
Inlet For The Main Relief Valve And Clutch Supply Rail | |
- Connect hose assembly (7) from the No. 2 flow meter inlet to Tooling (N) .
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| Illustration 28 | g00988640 |
Converter Outlet | |
- Connect hose assembly (8) from the outlet of the No. 2 flow meter to Tooling (U) .
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| Illustration 29 | g03127096 |
Inlet For The Transmission Lubrication Oil | |
- Connect lube line (9) from the test bench to Tooling (D). Maintain an oil pressure of 275 kPa (40 psi).
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| Illustration 30 | g00988647 |
Lubrication For The Spindle | |
- Connect a pressure gauge to Tooling (P) .
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| Illustration 31 | g00988649 |
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.
- Connect three pressure gauges to pressure taps (10), (11), and (12) .
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| Illustration 32 | g00988651 |
(10) "P3" Pressure (11) "P2" Pressure (12) "P1" Pressure | |
- Connect Tooling (Q) to six clutch solenoids, as shown.
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| Illustration 33 | g00988657 |
Cable connector (1-A) for No. 1 "FORWARD HIGH" solenoid (13) Cable connector (2-B) for No. 2 "REVERSE" solenoid (14) Cable connector (3-C) for No. 3 "FORWARD LOW" solenoid (15) Cable connector (4-D) for No. 4 "FIRST SPEED" solenoid (16) Cable connector (5-E) for No. 5 "SECOND SPEED" solenoid (17) Cable connector (6-F) for No. 6 "THIRD SPEED" solenoid (18) | |
- Connect Tooling (Q) to a suitable location, as shown.
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| Illustration 34 | g00988664 |
- Connect Tooling (Q) to a power source. Refer to Tool Operating Manual, NEHS0644 for the correct operating instructions.
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| Illustration 35 | g00877510 |
Tooling (Q) | |
- Cover The transmission. Use a clean suitable cover.
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| Illustration 36 | g00988665 |
Test Procedure
Solenoid Test
- Make sure that the harness is properly connected.
- Use Tooling (M) to perform the solenoid test.
- Record the values in Table 6.
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, SENR1220, "928G Wheel Loader and IT28G Integrated Toolcarrier 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 850 ± 25 rpm. Input flow should be 25.0 ± 4.0 L/min (6.6 ± 1.0 US gpm).
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| Illustration 37 | g02720621 |
- Shift the transmission through all speed ranges in order to eliminate air from the transmission controls.
- Stop the input rotation.
Torque Converter Inlet Relief Valve Check
- With the transmission in the NEUTRAL position, adjust the input rotation to 850 ± 25 rpm.
- Shift the transmission to FORWARD 1.
- Use Tooling (N) in order to momentarily block the flow at the converter outlet.
- The "P3" converter inlet pressure must be 1000 ± 140 kPa (145 ± 20 psi).
- Open Tooling (N) .
- Record the value in Table 7.
- Shift the transmission to the NEUTRAL position.
Low Idle Pressure Checks
- With the transmission in the NEUTRAL position, adjust the input rotation to 850 ± 25 rpm.
- Record the input flow, the "P1" pressure, and the "P2" pressure in Table 8.
- Verify the test points with the values in Table 4.
- Shift the transmission through each FORWARD and REVERSE speed range. Repeat Steps 2 and 3 for each position.
High Idle Pressure Checks
- With the transmission in the NEUTRAL position, adjust the input rotation to 2300± 25 rpm.
- Record the input flow, the oil cooler flow, the "P1" pressure, and the "P2" pressure in Table 9.
- Verify the test points with the values in Table 4.
- Shift the transmission through each FORWARD and REVERSE speed range. Repeat Steps 2 and 3 for each position.
- Shift the transmission to the NEUTRAL position.
- Stop the input rotation.
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 10.
- Remove the transmission from the test bench if the test bench oil supply is within specifications.
Specifications
| General Specifications | ||
| Description | High Idle | Low Idle |
| Input Speed | 2200 ± 25 rpm | 850 ± 25 rpm |
| Input Flow | 83.0 ± 4.0 L/min (21.9 ± 1.0 US gpm) |
25.0 ± 4.0 L/min (6.6 ± 1.0 US gpm) |
| Minimum Oil Cooler Flow | 66.0 L/min (17.5 US gpm) |
|
| Pressures | ||
| P1 | P2 + 276 ± 70 kPa (P2 + 40 ± 10 psi) |
P2 + 225 ± 70 kPa (P2 + 33 ± 10 psi) |
| P2 | 2137 ± 140 kPa (310 ± 20 psi) |
2137 ± 140 kPa (310 ± 20 psi) |
| P3 (1) | 1000 ± 140 kPa (145 ± 20 psi) |
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| Lubrication | 157 ± 30 kPa (22.8 ± 4.3 psi) |
|
| ( 1 ) | The transmission is in the FORWARD 1 position. The oil cooler flow is restricted. |
Transmission Bench Test Data Sheet
| CATERPILLAR | Transmission Bench Test Data Sheet | Test Date: |
| Model: 928G | ||
| 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 |
Torque Converter Inlet Relief Valve Check
| Torque Converter Inlet Relief Valve Check | Input Speed (850 ± 25 rpm) | kPa (psi) |
|||
Low Idle Pressure Checks
| Low Idle Pressure Checks | Input Speed (850 ± 25 rpm) | |||||||
| Gear Range | N | 1F | 2F | 3F | 4F | 1R | 2R | 3R |
| Input Flow |
||||||||
| "P1" Pressure | ||||||||
| "P2" Pressure | ||||||||
High Idle Pressure Checks
| High Idle Pressure Checks | Input Speed (2300 ± 25 rpm) | |||||||
| Gear Range | N | 1F | 2F | 3F | 4F | 1R | 2R | 3R |
| Input Flow |
||||||||
| Oil Cooler Flow | ||||||||
| "P1" Pressure | ||||||||
| "P2" Pressure | ||||||||
| Lubrication Pressure | ||||||||
ISO Particle Count
| ISO Particle Count | Sample the test bench oil supply. |
________/________Particle Count |
| ______________________________________ Technician |
______________________________________ Supervisor |