Bench Test Procedure for a 928G Wheel Loader andIT28G Integrated Toolcarrier Transmission with a Flexible Coupling Drive{3030, 3066, 3073} Caterpillar


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Bench Test Procedure for a 928G Wheel Loader and<BR>IT28G Integrated Toolcarrier Transmission with a Flexible Coupling Drive{3030, 3066, 3073} [REHS1629]
POWER TRAIN
CONTROL GP-TRANSMISSION HYD
Bench Test Procedure for a 928G Wheel Loader andIT28G Integrated Toolcarrier Transmission with a Flexible Coupling Drive{3030, 3066, 3073}
1.1. Introduction
2.1. Collecting the Test Data
3.1. Canceled Part Numbers and Replaced Part Numbers
4.1. Tools Needed
5.1. Installation Procedure
6.1. Test Procedure
7.2. Solenoid Test
8.2. Start Checks
9.2. Torque Converter Inlet Relief Valve Check
10.2. Low Idle Pressure Checks
11.2. High Idle Pressure Checks
12.2. Contamination Control
13.2. Specifications
14.1. Transmission Bench Test Data Sheet
15.2. Solenoid Test
16.2. Torque Converter Inlet Relief Valve Check
17.2. Low Idle Pressure Checks
18.2. High Idle Pressure Checks
19.2. ISO Particle Count
Integrated Toolcarrier:
IT28G (S/N: 8CR3600-UP; 9AR1061-UP)
Wheel Loader:
928G (S/N: 6XR3372-UP; 7SR2036-UP)

Introduction

Table 1
Revision     Summary of Changes in REHS1629    
01     Added new Introduction and Canceled Part Numbers section    

© 2012 AVSpare 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 AVSpare. 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 AVSpare.

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 AVSpare Repair Process Engineering:

  • Cat Dealer Techinical Communicator

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Table 2
Machine Model     Transmission Arrangement    
928G     201-3318    
IT28G     201-3318    

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.

------ WARNING! ------

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.

----------------------

------ WARNING! ------

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

----------------------

------ WARNING! ------

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. For additional information about tooling, consult AVSpare Service Technology Group (800) 542-8665.

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    
FT-0703 Support As.     1    
B     1U-5798     Drive Adapter Gp     1    
236-4489 Adapter     1    
0S-1585 Bolt (1/2-13X1.50 inch)     8    
5P-8245 Hard Washer     8    
8T-9515 Bolt (M10X1.50X40 mm)     6    
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     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    
5P-0492 Adapter     1    
7M-8485 O-Ring Seal     1    
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




    Illustration 1g00988581

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



    Illustration 2g00988582

  1. Use a hoist to install the transmission on the test bench. The weight of the transmission is 700 kg (1545 lb).



    Illustration 3g00992752

  1. Remove flex plate (1) .



    Illustration 4g00992753

  1. Install Tooling (B) on the torque converter, as shown.



    Illustration 5g00992755

    Note: Remove the ring gear from Tooling (B) .

  1. Install Tooling (B) .



    Illustration 6g00992759

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



    Illustration 7g00988587

    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.

  1. Install Tooling (D) on Tooling (C) .



    Illustration 8g00988590

  1. 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.




    Illustration 9g00988591

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



    Illustration 10g00988595

  1. 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) .




    Illustration 11g00988596

  1. Align the transmission with the input drive shaft.

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



    Illustration 12g00988597

  1. Install the drive shaft guard.



    Illustration 13g00988599



    Illustration 14g00988600

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



    Illustration 15g00988601

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



    Illustration 16g00992761

  1. Remove drain plug (2) .



    Illustration 17g00992763

  1. Remove cover (3) .



    Illustration 18g00992765

  1. Remove magnetic filter (4) .



    Illustration 19g03126817

  1. 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.




    Illustration 20g00988613

  1. Install Tooling (J) .



    Illustration 21g00988614

  1. Install Tooling (K) .



    Illustration 22g00988616

  1. Install Tooling (L) .



    Illustration 23g00992767

  1. Install Tooling (M) .



    Illustration 24g00992768

  1. Connect Tooling (N) to Tooling (M) .



    Illustration 25g03126837

  1. Install Tooling (U) .



    Illustration 26g00988626

  1. Install Tooling (P) .



    Illustration 27g03126843

  1. Connect hose assembly (5) from the pump supply to Tooling (T) .



    Illustration 28g00992773

    Outlet for the Transmission Oil Pump

  1. Connect hose assembly (6) from the No. 1 flow meter inlet to Tooling (K) .



    Illustration 29g00992774

    Inlet For The Main Relief Valve And Clutch Supply Rail

  1. Connect hose assembly (7) from the outlet of the No. 1 flow meter to Tooling (L) .



    Illustration 30g00992775

    Converter Outlet

  1. Connect hose assembly (8) from the No. 2 flow meter inlet to Tooling (N) .



    Illustration 31g03126856

    Inlet For The Transmission Lubrication Oil

  1. Connect hose assembly (9) from the outlet of the No. 2 flow meter to Tooling (U) .



    Illustration 32g00992778

    Lubrication For The Spindle

  1. Connect lube line (10) from the test bench to Tooling (D). Maintain an oil pressure of 275 kPa (40 psi).



    Illustration 33g00988649

    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.

  1. Connect a pressure gauge to Tooling (P) .



    Illustration 34g00992780

    (11) "P3" Pressure

    (12) "P2" Pressure

    (13) "P1" Pressure

  1. Connect three pressure gauges to pressure taps (11), (12), and (13) .



    Illustration 35g00992781

    Cable connector (1-A) for No. 1 "FORWARD HIGH" solenoid (14)

    Cable connector (2-B) for No. 2 "REVERSE" solenoid (15)

    Cable connector (3-C) for No. 3 "FORWARD LOW" solenoid (16)

    Cable connector (4-D) for No. 4 "FIRST SPEED" solenoid (17)

    Cable connector (5-E) for No. 5 "SECOND SPEED" solenoid (18)

    Cable connector (6-F) for No. 6 "THIRD SPEED" solenoid (19)

  1. Connect Tooling (Q) to six clutch solenoids, as shown.



    Illustration 36g00988664

  1. Connect Tooling (Q) to a suitable location, as shown.



    Illustration 37g00877510

    Tooling (Q)

  1. Connect Tooling (Q) to a power source. Refer to Tool Operating Manual, NEHS0644 for the correct operating instructions.



    Illustration 38g00988665

  1. Cover The transmission. Use a clean suitable cover.

Test Procedure

Solenoid Test

  1. Make sure that the harness is properly connected.

  1. Use Tooling (M) to perform the solenoid test.

  1. Record the values in Table 6.

Start Checks

    Note: Refer to Testing and Adjusting, SENR1220, "928G Wheel Loader and IT28G Integrated Toolcarrier 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.



    Illustration 39g02720621

  1. 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).

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

  1. Stop the input rotation.

Torque Converter Inlet Relief Valve Check

  1. With the transmission in the NEUTRAL position, adjust the input rotation to 850 ± 25 rpm.

  1. Shift the transmission to FORWARD 1.

  1. Use Tooling (N) in order to momentarily block the flow at the converter outlet.

  1. The "P3" converter inlet pressure must be 1000 ± 140 kPa (145 ± 20 psi).

  1. Open Tooling (N) .

  1. Record the value in Table 7.

  1. Shift the transmission to the NEUTRAL position.

Low Idle Pressure Checks

  1. With the transmission in the NEUTRAL position, adjust the input rotation to 850 ± 25 rpm.

  1. Record the input flow, the "P1" pressure, and the "P2" pressure in Table 8.

  1. Verify the test points with the values in Table 4.

  1. Shift the transmission through each FORWARD and REVERSE speed range. Repeat Steps 2 and 3 for each position.

High Idle Pressure Checks

  1. With the transmission in the NEUTRAL position, adjust the input rotation to 2300± 25 rpm.

  1. Record the input flow, the oil cooler flow, the "P1" pressure, and the "P2" pressure in Table 9.

  1. Verify the test points with the values in Table 4.

  1. Shift the transmission through each FORWARD and REVERSE speed range. Repeat Steps 2 and 3 for each position.

  1. Shift the transmission to the NEUTRAL position.

  1. Stop the input rotation.

Contamination Control

  1. Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.

  1. Record the results in Table 10.

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

Specifications

Table 4
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)    
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

Table 5
AVSpare     Transmission Bench Test Data Sheet     Test Date:    
Model: 928G
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    

Torque Converter Inlet Relief Valve Check

Table 7
Torque Converter Inlet Relief Valve Check     Input Speed (850 ± 25 rpm)     kPa
(psi)    

Low Idle Pressure Checks

Table 8
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

Table 9
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

Table 10
ISO Particle Count     Sample the test bench oil supply.
   
________/________Particle Count    

Table 11






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