Bench Test Procedure For A 910B Wheel Loader Transmission{3030, 3073} Caterpillar

Integrated Toolcarrier:

IT12 (S/N: 4NC1-UP)

Wheel Loader:

910 (S/N: 41Y1-UP)

G910 (S/N: 8GD1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS2842
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

Table 2

Machine Model	Transmission Arrangement
910B	9P-9640

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.

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.

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9585	Block Gp (Transmission Mounting)	1
	1U-9584	Rail As	2
	1U-9586	Swivel Head Support Gp	1
	FT1078	Support As	1
B	FT1075	Drive Adapter	1
	FT1081	Drive Ring	1
C	FT1492	Torque Converter Cover	1
D	FT0697	Key (Torque Converter Drive)	1
	FT0698	Input Drive Adapter	1
	FT0699	Retention Plate	1
E	1U-9722	Load Binder As (Ratchet Type)	2
F	1U-8304	Fitting	1
	9U-7445	Adapter	1
	1U-9879	Nipple (Quick Disconnect)	1
	3N-8699	Reducing Bushing	1
	2F-5277	Reducing Bushing	1
	3B-7749	Nipple (Close)	1
	1P-4578	Half Flange	2
	8T-8916	Bolt (7/16-14X1.50 inch)	4
	5P-8244	Washer	4
G	9M-6522	Connector	1
	2M-9780	O-Ring Seal	1
	5B-4855	Reducing Bushing	1
	7X-7646	Nipple (Quick Disconnect)	1
H	9M-6522	Connector	1
	2M-9780	O-Ring Seal	1
	5B-4855	Reducing Bushing	1
	7X-7646	Nipple (Quick Disconnect)	1
I	8C-9025	Coupler (Quick Disconnect)	1
	7X-7646	Nipple (Quick Disconnect)	1
	6B-9081	Reducing Bushing	2
	7F-6654	Nipple (Pipe)	2
	120-6843	Ball Valve	1
J	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
K	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
L	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
M	6V-0184	Test Cover	1
N	7S-8887	Nipple (Quick Disconnect)	1
	5P-3501	Adapter	1
	3J-1907	O-Ring Seal	1
P	7S-8887	Nipple (Quick Disconnect)	1
	5P-3501	Adapter	1
	3J-1907	O-Ring Seal	1
Q	FT1551	Shift Lever	1
R	8T-0862	Pressure Gauge (-100 to 500 kPa (-15 to 72 psi))	1
	6V-4144	Coupler	1
S	8T-0854	Pressure Gauge (0 to 1,000 kPa (0 to 145 psi))	1
	6V-4144	Coupler	1
T	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	3
	6V-4144	Coupler	3

Installation Procedure

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Illustration 1	g01210118

1. Install Tooling (A) on the test bench, as shown.

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Illustration 2	g01210130
Typical Example

2. Use a hoist to install the transmission on the test bench. The weight of the transmission is 477 kg (1052 lb).

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Illustration 3	g01210135

3. Install Tooling (B) .

4. Install Tooling (C) .

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Illustration 4	g01210153

5. Install Tooling (D) .

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Illustration 5	g01210160
Typical Example

6. Align the transmission with the input drive shaft.

7. Connect the input drive shaft to Tooling (D) .

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Illustration 6	g01210163
Typical Example

8. Install the drive shaft guard.

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Illustration 7	g01210166

9. Fasten the transmission to the test bench by using Tooling (E) .

10. Remove the oil drain plug in order to allow the oil to drain into the test bench sump.

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Illustration 8	g01210196

11. Remove the tube assembly between the pump and opening (1) .

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Illustration 9	g01210193

12. Install Tooling (F) .

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Illustration 10	g01210198

13. Remove the plug and install Tooling (G) .

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Illustration 11	g01210199

14. Remove the plug and install Tooling (H) .

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Illustration 12	g01210201

15. Install Tooling (I) to Tooling (H) .

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Illustration 13	g01210202
(2) Supply Oil to the Transmission Pump

16. Connect hose assembly (2) from the test bench to Tooling (F) .

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Illustration 14	g01210230
(3) Lubrication Inlet

17. Connect hose assembly (3) from the outlet of the flow meter on the test bench to Tooling (G) .

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Illustration 15	g01210232
(4) Torque Converter Outlet

18. Connect hose assembly (4) from the inlet of the flow meter on the test bench to Tooling (I) .

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Illustration 16	g01210250

19. Remove the cover from the top of the transmission.

20. Remove the pipe plugs from the "P1", "P2", and "P3" pressure taps in top of the control valve.

21. Install Tooling (J) .

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Illustration 17	g01210252

22. Install Tooling (K) .

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Illustration 18	g01210253

23. Install Tooling (L) .

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Illustration 19	g01210255

24. Install Tooling (M) .

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Illustration 20	g01210256

25. Remove the plug and install Tooling (N) .

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Illustration 21	g01210280

26. Remove the plug and install Tooling (P) .

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Illustration 22	g01210257
(5) Speed Clutch and Initial Pressure "P1"

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

27. Connect a pressure line (5) to Tooling (J) .

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Illustration 23	g01210259
(6) Directional Clutch Pressure "P2"

28. Connect a pressure line (6) to Tooling (K) .

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Illustration 24	g01210260
(7) Torque Converter Inlet Pressure "P3"

29. Connect a pressure line (7) to Tooling (L) .

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Illustration 25	g01210292
(8) Lubrication Pressure

30. Connect a pressure line (8) to Tooling (N) .

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Illustration 26	g01210297
(9) Pump Pressure

31. Connect a pressure line (9) to Tooling (P) .

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Illustration 27	g01210311

32. Install Tooling (Q) with a 12.7 mm (0.5 inch) thick spacer between the top of the transmission case and the adapter.

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Illustration 28	g00988665

33. Cover the transmission. Use a clean suitable cover.

Test Procedure

Start Checks

Note: Refer to Testing and Adjusting, SENR7988-01, "910 Power Shift Transmission" 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.

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Illustration 29	g02720621

2. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 750 ± 5 rpm.

3. Shift the transmission through all speed ranges in order to eliminate air from the transmission controls.

4. Stop the input rotation.

Initial Pressure

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Illustration 30	g01210425

1. Remove load piston plug (10) from the control valve.

2. Shift the transmission to NEUTRAL.

3. Adjust input rotation to 750 ± 5 rpm.

4. The initial "P1" clutch pressure must be 531 ± 35 kPa (77 ± 5 psi).

5. Record the value in Table 6.

6. Stop the input rotation.

7. Install load piston plug (10) .

Pressure Differential Valve

1. Shift the speed selector to THIRD.

2. Adjust input rotation to 750 ± 5 rpm.

3. The "P2" directional clutch pressure must remain at 0 kPa (0 psi).

4. Record the value in Table 7.

5. Adjust input rotation to 2400 ± 5 rpm.

6. The "P2" directional clutch pressure must remain at 0 kPa (0 psi).

7. Shift the speed selector to NEUTRAL and then shift the speed selector into any gear range.

8. The "P2" directional clutch pressure must increase to normal pressure.

9. Record the values in Table 8.

Torque Converter Inlet Relief Valve

1. With the transmission in the NEUTRAL position, adjust the input rotation to 750 ± 5 rpm.

2. Shift the transmission to FORWARD 1.

3. Use Tooling (I) in order to momentarily block the flow at the torque converter outlet.

4. The "P3" torque converter inlet pressure must be 896 ± 55 kPa (130 ± 8 psi).

5. Open Tooling (I) .

6. Record the value in Table 9.

7. Shift the transmission to the NEUTRAL position.

Neutralizer Valve

1. Place the direction selector lever in any position except NEUTRAL.

2. Place the speed selector lever in THIRD range.

3. Adjust input rotation to 2400 ± 5 rpm.

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Illustration 31	g01210438

4. Open the neutralizer pedal port (11) to the DRAIN position.

5. The "P2" directional clutch pressure must drop to 0 kPa (0 psi).

   Note: The "P1" speed clutch pressure may drop temporarily, but the pressure must return to full pressure.

6. Close the neutralizer pedal port (11) .

7. The "P2" pressure must return to normal.

8. Record the values in Table 10.

Low Idle Pressure

1. Adjust input rotation to 750 ± 5 rpm.

2. Record the "P1" pressure, "P2" pressure, the "P3" pressure, the lubrication pressure, and the lube flow in all ranges in Table 11.

3. Compare values with Table 4.

High Idle Pressure

1. Adjust input rotation to 2400 ± 5 rpm.

2. Record the "P1" pressure, "P2" pressure, the lubrication pressure, and the lube flow in all ranges in Table 12.

3. Compare values with Table 4.

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 13.

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

Specifications

Table 4

Specifications
Description	High Idle	Low Idle
Input Speed	2400 ± 5 rpm	750 ± 5 rpm
Minimum Lube Flow (1)	40.5 L/min (10.7 US gpm)	7 L/min (1.8 US gpm)
Pressures
"P1" Initial (2)	-	531 ± 35 kPa (77 ± 5 psi)
"P1"	2590 ± 105 kPa (375.7 ± 15.2 psi)	1910 kPa (277 psi) Minimum
"P2"	P1 - 380 ± 55 kPa (P1 - 55 ± 8 psi)	P1 - 380 ± 55 kPa (P1 - 55 ± 8 psi)
"P3" (3)	-	896 ± 55 kPa (130 ± 8 psi)
Lubrication	88 ± 20 kPa (12.8 ± 3 psi)	4 kPa (0.6 psi) Minimum

( 1 )	The maximum difference in lube flow between gear ranges must not exceed 3.5 L/min (0.9 US gpm).
( 2 )	The load piston plug (10) is removed from transmission controls.
( 3 )	Flow is restricted and the selector is in FORWARD 1.

Transmission Bench Test Data Sheet

Table 5

CATERPILLAR	Transmission Bench Test Data Sheet	Test Date:
		Model: 910B
Work Order:		Serial No.:

Initial Pressure Check

Table 6

"P1" Clutch Pressure

Input Speed (750 ± 5 rpm) Gear Range NEUTRAL Removed Load Piston Plug (10)

kPa (psi)

Pressure Differential Valve

Table 7

"P2" Directional Clutch Pressure	Input Speed (750 ± 5 rpm)
Gear Range THIRD	kPa (psi)

Table 8

"P2" Directional Clutch Pressure	Input Speed (2400 ± 5 rpm)
Gear Range THIRD	kPa (psi)
Any Gear Range Except NEUTRAL	kPa (psi)

Torque Converter Inlet Relief Valve

Table 9

"P3" Torque Converter Inlet Pressure

Input Speed (750 ± 5 rpm) Gear Range FORWARD 1 Restricted Torque Converter Outlet

kPa (psi)

Neutralizer Valve

Table 10

"P2" Directional Clutch Pressure	Input Speed (2400 ± 5 rpm) Speed Selector In THIRD Direction Selector In Any Position Except NEUTRAL
Open Neutralizer Pedal Port	kPa (psi)
Closed Neutralizer Pedal Port	kPa (psi)

Low Idle Pressure Checks

Table 11

Low Idle Pressure Checks			Input Speed (750 ± 5 rpm)
Gear Range	N	1F	2F	3F	1R
Minimum Lube Flow
"P1" Pressure
"P2" Pressure
Lubrication Pressure

High Idle Pressure Checks

Table 12

High Idle Pressure Checks			Input Speed (2400 ± 5 rpm)
Gear Range	N	1F	2F	3F	1R
Minimum Lube Flow
"P1" Pressure
"P2" Pressure
Lubrication Pressure

Contamination Control

Table 13

ISO Particle Count

Sample the test bench oil supply.

________/________Particle Count

Table 14

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