- Wheel Loader
- 980C (S/N: 13B1-UP)
Introduction
| Revision | Summary of Changes in REHS2298 |
| 03 | Standardized. |
| 02 | Added new Introduction and Canceled Part Numbers section |
© 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- 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 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:
- Cat Dealer Techinical Communicator
- Dealer Solution Network
- Cat Technical Representative
- Knowledge Network
| Machine Model | Transmission Arrangement |
| 980C |
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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| 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.
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| 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 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
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.
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | Rail As | 2 | |
| Bracket | 2 | ||
| Crossmember | 1 | ||
| Bolt (3/4-10X5.0 inch) | 4 | ||
| Hard Washer | 8 | ||
| Full Nut | 4 | ||
| Bolt (3/4-10X3.0 inch) | 8 | ||
| Hard Washer | 8 | ||
| B | Drive Adapter Gp | 1 | |
| C | Spindle Adapter | 1 | |
| Bolt(1) (3/8-16X1.25 inch) | 2 | ||
| Bolt(2) (3/8-16X1.75 inch) | 2 | ||
| Hard Washer | 4 | ||
| D | Spindle Gp | 1 | |
| Bolt (1/2-13X2.00 inch) | 4 | ||
| Lockwasher | 4 | ||
| E | Adapter (Drive) | 1 | |
| F | Drive Adapter (Key)(3) (Key) | 1 | |
| G | Drive Adapter(4) | 1 | |
| H | Link Bracket As | 2 | |
| Link Bracket As(5) | 2 | ||
| Bolt (3/4-10X1.25 inch) | 2 | ||
| Hard Washer | 2 | ||
| Ratcheting Turnbuckle | 4 | ||
| AA | Adapter (Flange) | 1 | |
| J | Fitting | 1 | |
| Adapter (Flange) | 1 | ||
| Half Flange | 2 | ||
| Nipple (Quick Disconnect) | 1 | ||
| Bolt (7/16-14X1.125 inch) | 2 | ||
| Bolt (7/16-14X1.50 inch) | 2 | ||
| Washer | 8 | ||
| Fitting As (Quick Disconnect) | 1 | ||
| K | Fitting | 1 | |
| Adapter (Flange) | 1 | ||
| Half Flange | 2 | ||
| Nipple (Quick Disconnect) | 1 | ||
| Bolt (7/16-14X1.125 inch) | 4 | ||
| Washer | 4 | ||
| Fitting As (Quick Disconnect) | 1 | ||
| L | Fitting | 1 | |
| Adapter (Flange) | 1 | ||
| Half Flange | 2 | ||
| Nipple (Quick Disconnect) | 1 | ||
| Bolt (7/16-14X1.25 inch) | 4 | ||
| Washer | 4 | ||
| Fitting As (Quick Disconnect) | 1 | ||
| M | Ball or Gate Valve | 1 | |
| Nipple (Quick Disconnect) | 1 | ||
| Coupler (Quick Disconnect) | 1 | ||
| Nipple 1.0 Shoulder | 1 | ||
| N | Nipple (Quick Disconnect) | 1 | |
| O-Ring | 1 | ||
| P | Shift Levers | 1 | |
| Q | Nipple (Pipe) | 1 | |
| Nipple (Quick Disconnect) | 1 | ||
| R | Nipple (Pipe) | 1 | |
| Nipple (Quick Disconnect) | 1 | ||
| S | Nipple (Pipe) | 1 | |
| Nipple (Quick Disconnect) | 1 | ||
| T | Test Cover | 1 | |
| U | Air Pressure Regulator | 1 | |
| Reducer Bushing | 2 | ||
| Nipple (Quick Disconnect) | 1 | ||
| Nipple (Pipe) | 1 | ||
| V | Pressure Gauge (-100 to 500 kPa (-15 to 72 psi)) | 1 | |
| W | Pressure Gauge (0 to 1,000 kPa (0 to 145 psi)) | 1 | |
| X | Pressure Gauge (0 to 1,000 kPa (0 to 145 psi)) | 1 | |
| Pressure Gauge (0 to 4,000 kPa (0 to 580 psi)) | 1 | ||
| Y | Pressure Gauge (0 to 4,000 kPa (0 to 580 psi)) | 1 | |
| Z | Pressure Gauge (0 to 4,000 kPa (0 to 580 psi)) | 1 | |
| (1) | These bolts are used in the top locations. |
| (2) | These bolts are used in the bottom locations. |
| (3) | This drive adapter is used with the small drive shaft. |
| (4) | This drive adapter is used with the large drive shaft. |
| (5) | This tooling is used with Tooling (C). |
| (6) | Use this gauge for the initial pressure "P1". |
FT Drawings
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| Illustration 3 | g06034822 |
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FT-1551 | |
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| Illustration 4 | g06034829 |
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FT-1551 (Assembly) (1) Item 1 Bracket As. Qty: 1 (2) Item 2 Block Qty: 2 (3) Item 3 Pin Qty: 4 (4) Item 4 Rod Qty: 2 (5) Item 5 Lever Qty: 2 (6) Item 6 Boss Qty: 2 (7) Item 7 Lever As. Items 4, 5, and 6 Qty: 2 (8) (9) (10) Item 10 Link Qty: 2 | |
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| Illustration 5 | g06050729 |
|
FT-2424 | |
Installation Procedure
- Install Tooling (A) to the test bench.
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Illustration 7 g01188580 - Use a hoist to install the transmission on the test bench. The weight of the transmission is
1470 kg (3241 lb) .Show/hide table
Illustration 8 g01188583 - Install Tooling (B) on the torque converter.
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Illustration 9 g01188588 - Install Tooling (C) to the transmission case.
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Illustration 10 g01188589 - Install Tooling (D) on Tooling (C).
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Illustration 11 g01188594 - Tighten the collet on Tooling (D) to connect Tooling (D) to Tooling (B).
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Illustration 12 g01188596 - Install Tooling (E) to the input shaft of Tooling (D).
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Illustration 13 g01188597 - 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 14 g01188600 - Align the transmission with the input drive shaft.
- Connect the input drive shaft to Tooling (F).
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Illustration 15 g01188602 - Install the drive shaft guard.
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Illustration 16 g03802221 - Tighten all four castle nuts and jack bolts.
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Illustration 17 g01188603 Show/hide table
Illustration 18 g06049919 - Install Tooling (H) to the output end of the transmission.
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Illustration 19 g01188607 - Install Tooling (H) to the input end of the transmission.
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Illustration 20 g01204479 - Remove drain plug (1).
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Illustration 21 g03122597 - Install Tooling (AA).
Note: Tooling (AA) will activate the drain valve.
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Illustration 22 g01204715 - Remove the cover, the magnetic tube, and the screen (2).
Note: This will allow oil to drain from the transmission during the test procedure.
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Illustration 23 g01204428 - Install Tooling (J).
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Illustration 24 g01204458 - Install Tooling (K).
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Illustration 25 g01204462 - Install Tooling (L).
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Illustration 26 g01204466 - Install Tooling (M).
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Illustration 27 g01204475 (3) Supply Oil - Connect hose assembly (3) from the test bench oil supply to Tooling (J).
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Illustration 28 g01204483 (4) Torque Converter Outlet - Connect hose assembly (4) from Tooling (K) to the No. 1 flow meter inlet.
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Illustration 29 g01204486 (5) Lubrication Inlet - Connect hose assembly (5) from the No. 1 flow meter outlet to Tooling (M).
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Illustration 30 g01204494 - Install Tooling (N).
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Illustration 31 g01204504 - Install Tooling (P).
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Illustration 32 g01204511 - Install Tooling (Q).
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Illustration 33 g01204587 - Install Tooling (R).
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Illustration 34 g01204591 - Install Tooling (S).
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Illustration 35 g01204626 - Install Tooling (T).
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Illustration 36 g01204638 - Remove the plug and install Tooling (U).
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Illustration 37 g01204666 - Connect an air line (6) to the hold valve.
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Illustration 38 g01204670 (V) Lubrication Pressure - Connect Tooling (V) to Tooling (L).
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Illustration 39 g01204677 (W) Torque Converter Outlet Pressure - Connect Tooling (W) to Tooling (K).
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Illustration 40 g01204686 (X) Speed Clutch and Initial Pressure "P1" - Install Tooling (X).
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Illustration 41 g01204689 (Y) Direction Clutch Pressure "P2" - Install Tooling (Y).
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Illustration 42 g01204693 (Z) Torque Converter Inlet Pressure "P3" - Install Tooling (Z).
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Illustration 43 g01204721 - Connect lube line (7) from the test bench to Tooling (D). Maintain an oil pressure of
275 kPa (40 psi) .Show/hide table
Illustration 44 g01188647 - Cover the transmission. Use a suitable clean cover.
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| Illustration 6 | g06050738 |
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 to34 °C (95 °F) . Maintain this temperature for the duration of the test. - Adjust the input flow to
45 ± 4 L/min (12 ± 1 US gpm) .Show/hide table
Illustration 45 g02720621 - With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 30 rpm.
- Shift the transmission through all gears to eliminate air from the transmission controls.
- The lubrication pressure must be between
17 kPa (3 psi) and31 kPa (5 psi) .Note: If there is no lube pressure after 3 seconds, stop input rotation and check connections on the test bench transmission.
- Record the value in Table 7.
- 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 F1 X X F2 X X F3 X X F4 X X R1 X X R2 X X R3 X X R4 X X - Stop the input rotation.
- Stop the input flow.
Note: Refer to Testing and Adjusting, SENR7755, "980C Wheel Loader Power Train" for the correct adjusting procedures.
Primary Pressure Check
- Remove load piston plug (8) from the top of the controls.
- Shift the transmission to NEUTRAL.
- Adjust the input rotation to 700 ± 30 rpm.
- Adjust the input flow to
45 ± 4 L/min (12 ± 1 US gpm) . - The initial "P1" pressure must be
531 ± 35 kPa (77 ± 5 psi) . - Record the value in Table 8.
- Stop the input shaft rotation and oil supply flow.
- Install load piston plug (8) in the top of the controls.
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| Illustration 46 | g01204731 |
Differential Valve
- Place the direction selector in any position that is not NEUTRAL.
- Adjust input flow to
136 ± 4 L/min (36 ± 1 US gpm) and input rotation to 2100 ± 30 rpm. "P2" must remain at0 kPa (0 psi) . - Record the value in Table 9.
- Shift the direction selector to NEUTRAL. "P2" must rise to normal pressure.
- Record the value in Table 9.
Neutralizer Valve
- Adjust input flow to
136 ± 4 L/min (36 ± 1 US gpm) and input rotation to 2100 ± 30 rpm. - Place the direction selector in any position that is not NEUTRAL.
- Supply air at
200 ± 34 kPa (29 ± 5 psi) to the neutralizer valve. "P2" must drop to0 kPa (0 psi) . - Relieve air pressure behind the neutralizer valve. "P2" must return to normal pressure.
- Record values in Table 10.
Torque Converter Inlet Ratio Valve
- Adjust the input flow to
45 ± 4 L/min (12 ± 1 US gpm) . Maintain this flow during this check. - With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 30 rpm.
- Shift the transmission to FORWARD 1.
- Use Tooling (M) to momentarily block the lube flow.
- The torque converter inlet pressure must be
896 ± 55 kPa (130 ± 8 psi) . - Open the lube flow.
- Record the value in Table 11.
Lube Circuit Check
- Adjust the input flow until the lube flow is
95 ± 4 L/min (25 ± 1 US gpm) . Maintain this flow during this check. - Adjust the input rotation to 700 ± 30 rpm.
- Shift the transmission to FORWARD 3.
- Adjust the input rotation to 1750 ± 30 rpm.
- The lubrication pressure must be between
214 kPa (31 psi) and248 kPa (36 psi) . - Record the value in Table 12.
Clutch Leakage Check
- Adjust the input flow to
136 ± 4 L/min (36 ± 1 US gpm) . Maintain this flow during this check. - Adjust the input rotation to 700 ± 30 rpm.
- Shift the transmission to the FORWARD 1 position.
- Adjust the input rotation to 2100 ± 30 rpm.
- Record the input flow in Table 13.
- Record the lube flow in Table 13.
- The leakage is obtained by subtracting the lube flow from the input flow.
- Record the calculation in Table 13.
- Adjust the input rotation to 700 ± 30 rpm.
- Shift the transmission through positions FORWARD 2, FORWARD 3, FORWARD 4, REVERSE 1, REVERSE 2, REVERSE 3, REVERSE 4, and NEUTRAL. Repeat Steps 4 through 9 for each gear range.
Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD to REVERSE.
- The average lube flow of the FIRST, THIRD, and FOURTH gear ranges must not be less than
123.3 L/min (32.6 US gpm) . - The difference in lube flow between the FIRST, THIRD, and FOURTH gear ranges and between FORWARD and REVERSE shall be no more than
2.3 L/min (0.6 US gpm) . - The difference in lube flow between SECOND and the highest amount of the above ranges must be
5.7 ± 3 L/min (1.5 ± 0.8 US gpm) . - The lube flow in NEUTRAL must be greater than the average of the FIRST, THIRD, and FOURTH gear ranges.
- Record the calculations in Table 13.
- Adjust the input rotation to 700 ± 30 rpm.
Contamination Control
- Drain all oil from the transmission.
- Take an oil sample of the test bench oil supply. Oil contamination must be below ISO 16/13.
- Record the results in Table 14.
- Remove the transmission from the test bench if the test bench oil supply is within specifications.
Transmission Bench Test Data Sheet
| CATERPILLAR | Transmission Bench Test Data Sheet | Test Date:_______ |
| Model:_______ | ||
| Work Order:_______ | Serial No. :_______ | |
Specifications
| Specifications | ||
|---|---|---|
| Description | High Idle | Low Idle |
| Input Speed | 2100 ±30 rpm | 700 ± 30 rpm |
| Input Flow | |
|
| Minimum Lube Flow | |
|
| Pressures | ||
| "P1" Initial(1) | - | |
| P1 | |
|
| P2 | P1 − 379 ± 55 kPa
(P1 − 55 ± 8 psi) |
P1 − 379 ± 55 kPa
(P1 − 55 ± 8 psi) |
| P3(2) | - | |
| Torque Converter Outlet | |
|
| (1) | The load piston plug is removed and the transmission is in the NEUTRAL position. |
| (2) | The flow for the torque converter outlet is restricted. |
Start Checks
| Lubrication Pressure | Input Speed (700 ± 30 rpm)
Input Flow |
_______kPa _______(psi) |
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Primary Pressure Check
| Initial Pressure | Input Speed (700 ± 30 rpm)
Input Flow |
_______kPa _______(psi) |
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Differential Valve
| Differential Valve | Input Speed (2100 ± 30 rpm)
Input Flow |
| Any Gear Range (excluding NEUTRAL) | _______kPa _______(psi) |
| Gear Range NEUTRAL | _______kPa _______(psi) |
Neutralizer Valve
| Neutralizer Valve | Any Gear Range (excluding NEUTRAL)
Input Speed (2100 ± 30 rpm) Lube Flow |
"P2" Pressure
(Air supply at |
_______kPa _______(psi) |
| "P2" Pressure
(Air pressure behind Neutralizer Valve) |
_______kPa _______(psi) |
Torque Converter Inlet Ratio Valve
| Pressure for Torque Converter Inlet Ratio Valve | Input Speed (700 ± 30 rpm)
Input Flow |
_______kPa _______(psi) |
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Lube Circuit Check
| Lube Circuit Check | Gear Range FORWARD 3
Input Speed (1750 ± 30 rpm) Lube Flow |
| Lubrication Pressure | _______kPa _______(psi) |
Clutch Leakage Check
| Clutch Leakage Check | Input Speed (2100 ± 30 rpm)
Input Flow |
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|---|---|---|---|---|---|---|---|---|---|
| Gear Range | N | F1 | F2 | F3 | F4 | R1 | R2 | R3 | R4 |
| Input Flow | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ |
| Lube Flow | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ |
| Leakage | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ |
| Averages | 1F+3F+4F/3=_____________ | 1R+3R+4R/3=_____________ | |||||||
Contamination Control
| ISO Particle Count | Sample the test bench oil supply. *ISO 4406 is 16/13 or better |
________/________Particle Count |
______________________________________ Technician |
______________________________________ Supervisor |