- Motor Grader:
- 24H (S/N: 7KK1-UP)
Introduction
| Revision | Summary of Changes in REHS2369 |
| 02 | Standardized. |
| 01 | Added new Introduction and Canceled Part Numbers section. |
© 2015 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 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 |
| 24H | 8E-1298 |
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 in order 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 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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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 Tools Division (800) 542-8665.
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 1U-9584 | Rail As | 2 |
| 4C-9998 | Bracket As | 2 | |
| 159-0747 | Crossmember | 1 | |
| 6V-3669 | Bolt (20-2.00X80 mm) | 6 | |
| 8T-3282 | Hard Washer | 6 | |
| 1D-4590 | Bolt (5/8-11X4.75 inch) | 4 | |
| 5P-8247 | Hard Washer | 8 | |
| 4K-0367 | Full Nut | 4 | |
| B | 9U-7444 | Adapter | 1 |
| C | 4C-4627 | Adapter | 1 |
| 4L-7124 | Bolt (1/2-20X1.25 inch) | 4 | |
| 3B-4508 | Lockwasher | 4 | |
| D | 136-3647 | Drive Adapter As | 1 |
| 2J-5245 | Bolt (3/8-16X1.25 inch) | 4 | |
| 3B-4506 | Lockwasher | 4 | |
| E | 1U-9131 | Drive Adapter (KEY) (1) | 1 |
| F | 1U-9359 | Drive Adapter (2) | 1 |
| G | 1U-9722 | Load Binder As (Ratchet Type) | 4 |
| 439-3940 | Link Bracket As (Front) | 2 | |
| 439-3939 | Link Bracket As (Rear) | 2 | |
| 0S-1592 | Bolt (5/8-11X1.25inch) | 2 | |
| 1A-8063 | Bolt (3/4-10X2.5 inch) | 2 | |
| 5P-8247 | Hard Washer | 2 | |
| 5P-8248 | Hard Washer | 2 | |
| H | 8C-9024 | Fitting As (Plain) | 1 |
| 1U-8301 | Fitting | 1 | |
| 9U-7445 | Adapter | 1 | |
| 1P-4578 | Half Flange | 2 | |
| 6V-3965 | Fitting As (Quick Disconnect) | 1 | |
| 3J-1907 | O-Ring Seal | 1 | |
| 8T-6973 | Bolt (7/16-14X1.125 inch) | 4 | |
| 8T-5360 | Hard Washer | 4 | |
| Q | 8C-9024 | Fitting As (Plain) | 1 |
| 1U-8301 | Fitting | 1 | |
| 9U-7445 | Adapter | 1 | |
| 1P-4578 | Half Flange | 2 | |
| 6V-3965 | Fitting As (Quick Disconnect) | 1 | |
| 3J-1907 | O-Ring Seal | 1 | |
| 8T-6973 | Bolt (7/16-14X1.125 inch) | 4 | |
| 8T-5360 | Hard Washer | 4 | |
| J | 8C-9024 | Fitting As (Plain) | 1 |
| 1U-8304 | Fitting | 1 | |
| 9U-7445 | Adapter | 1 | |
| 1P-4578 | Half Flange | 2 | |
| 6V-3965 | Fitting As (Quick Disconnect) | 1 | |
| 3J-1907 | O-Ring Seal | 1 | |
| 8T-6973 | Bolt (7/16-14X1.125 inch) | 4 | |
| 8T-5360 | Hard Washer | 4 | |
| K | 6V-3965 | Fitting As (Quick Disconnect) | 1 |
| 3J-1907 | O-Ring Seal | 1 | |
| L | 8C-9024 | Fitting As (Plain) | 1 |
| 8C-9025 | Quick Coupler | 1 | |
| 3B-7749 | Fitting | 1 | |
| 120-6843 | Ball Valve | 1 | |
| M | 9U-7500 | Transmission Analyzer Tool Gp | 1 |
| OR | |||
| 277-2362 | Transmission Analyzer III Gp | 1 | |
| 306-0397 | Extension Cable (Transmission Analyzer) | 1 | |
| 9U-7495 | Adapter Cable As | 1 | |
| N | 8T-0855 | Pressure Gauge (0 to 4,000 kPa (0 to 580 psi)) | 2 |
| 6V-4144 | Coupler | 2 | |
| R | 8T-0854 | Pressure Gauge (0 to 1,000 kPa (0 to 140 psi)) | 1 |
| 6V-4144 | Coupler | 1 | |
| P | 8T-0863 | Pressure Gauge (0 to 250 kPa (0 to 36 psi)) | 1 |
| 6V-4144 | Coupler | 1 | |
| ( 1 ) | This drive adapter is used with the small drive shaft. |
| ( 2 ) | This drive adapter is used with the large drive shaft. |
Installation Procedure
- Assemble Tooling (A) on the rails of the test bench.
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| Illustration 3 | g03885160 |
- Use a hoist to install the transmission on the test bench. The weight of the transmission is 1474 kg (3250 lb).
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| Illustration 4 | g03885222 |
- Remove drain plug (1) .
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| Illustration 5 | g03885235 |
- Install Tooling (B) .
Note: Tooling (B) will activate the drain valve, allowing the oil to drain into the test bench.
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| Illustration 6 | g01095391 |
- Remove cover plate (2) .
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| Illustration 7 | g03885247 |
- Remove filter assembly (3) .
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| Illustration 8 | g03885248 |
- Install Tooling (C) to the input yoke.
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| Illustration 9 | g03885250 |
- Install Tooling (D) to Tooling (C) .
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| Illustration 10 | g03885251 |
- Install Tooling (E) to Tooling (D) .
Note: Tooling (E) will adapt to the small drive shaft. If you are using the large drive shaft, install Tooling (F) on Tooling (E) .
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| Illustration 11 | g03885252 |
- Align the transmission with the input drive shaft.
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| Illustration 12 | g03885253 |
- Connect the input drive shaft to Tooling (E) .
- Install the drive shaft guard.
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| Illustration 13 | g03885256 |
- Tighten all four castle nuts and jack bolts.
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| Illustration 14 | g03375318 |
- Install Tooling (G) to the output end of the transmission.
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| Illustration 15 | g03885258 |
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| Illustration 16 | g03885260 |
- Install Tooling (G) to the input end of the transmission.
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| Illustration 17 | g03885262 |
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| Illustration 18 | g03885264 |
- Install Tooling (H) .
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| Illustration 19 | g03885269 |
- Install Tooling (Q) .
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| Illustration 20 | g03885186 |
- Install Tooling (J) .
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| Illustration 21 | g03885830 |
- Install Tooling (K) .
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| Illustration 22 | g03885832 |
- Connect Tooling (L) to Tooling (Q) .
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| Illustration 23 | g03885195 |
- Connect hose assembly (4) from the pressurized flow meter to Tooling (H) .
Note: The flow meter will measure the flow of the supply oil.
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| Illustration 24 | g03885834 |
(4) Supply Oil | |
- Connect hose assembly (5) from Tooling (L) to the No. 2 flow meter inlet.
Note: The No. 2 flow meter will measure the torque converter inlet oil that is returning to the test bench.
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| Illustration 25 | g03885835 |
(5) Torque Converter Inlet Oil | |
- Connect hose assembly (6) from the outlet of the No. 2 flow meter to Tooling (J) .
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| Illustration 26 | g03885839 |
(6) Transmission Lubrication Oil | |
- Connect a pressure gauge to pressure tap (7) .
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| Illustration 27 | g03885841 |
Transmission Control Supply Pressure | |
Note: If you are using individual pressure gauges to measure the pressures, refer to Table 3 for the correct pressure gauges.
- Connect a pressure gauge to pressure tap (8) .
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| Illustration 28 | g03885849 |
Torque Converter Inlet Oil Pressure | |
- Connect a pressure gauge (9) to Tooling (K) .
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| Illustration 29 | g03885853 |
Transmission Lubrication Pressure Tap | |
- Connect pressure gauges to pressure taps (10) and (11) .
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| Illustration 30 | g03885860 |
(10) Speed Clutch Pressure "P1" (11) Direction Clutch Pressure "P2" | |
- Connect Tooling (M) to the transmission.
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| Illustration 31 | g03885864 |
- Connect Tooling (M) to a suitable location.
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| Illustration 32 | g03885865 |
- Connect Tooling (M) to a power source. Refer to Tool Operating Manual, NEHS0644 or Tool Operating Manual, NEHS0996 for the correct operating instructions.
Note: Make sure that the transmission is secured to the test bench. Tighten all bolts to the proper torque.
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| Illustration 33 | g01095668 |
Tooling (M) | |
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| Illustration 34 | g02629190 |
Tooling (M) | |
Test Procedure
TA3 Navigation
- Select "Motor Graders".
- Select "24H-24V".
Harness Test (TA3 only)
- Make sure that the harness is properly connected.
- Use Tooling (M) to perform the harness test.
- Record the values in Table 7.
Note: Do not continue testing until Harness Test passes.
Solenoid Test (TA2 only)
- Make sure that the harness is properly connected.
- Use Tooling (M) to perform the solenoid test.
- Record the values in Table 7.
Note: Do not continue testing until Solenoid Test passes.
Start Checks
- The preferred oil is SAE 10 oil viscosity grade. Warm SAE 10 oil viscosity grade 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, SENR1417, "24H Motor Grader Power Train" for the correct adjusting procedures.
- Adjust the input flow to 72 ± 4 L/min (19 ± 1 US gpm).
- With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 35 rpm.
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| Illustration 35 | g02720621 |
- The minimum transmission lubrication pressure should be 28 kPa (4 psi).
Note: If there is no lube pressure after 3 seconds, stop input rotation and check connections on test bench and transmission.
- Record the value in Table 8.
- Shift the transmission through all directions and through all speed ranges to eliminate air from the transmission controls.
- Confirm the correct clutch engagement with Table 4.
Show/hide table
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 F5 X X F6 X X R1 X X R2 X X R3 X X
- Stop the input rotation.
- Stop the input flow.
Primary Pressure Check
- Remove cover (12) .
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| Illustration 36 | g03885870 |
- Remove load piston plug (13) .
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| Illustration 37 | g03885872 |
- Install cover (12) .
- Adjust the input flow to 72 ± 4 L/min (19 ± 1 US gpm).
- With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 35 rpm.
- The "P1" pressure must be 620 ± 34 kPa (90 ± 5 psi).
- Record the value in Table 9.
- Stop the input rotation.
- Stop the input flow.
- Remove cover (12) .
- Install load piston plug (13) .
- Install cover (12) .
Torque Converter Inlet Ratio Valve
- Adjust the input flow to 72 ± 4 L/min (19 ± 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 ± 35 rpm.
- Shift the transmission to FORWARD 1.
- Use Tooling (L) to momentarily block the lube flow.
- The torque converter inlet pressure must be 896 ± 83 kPa (130 ± 12 psi).
- Open the lube flow.
- Record the value in Table 10.
Lube Circuit Check
- Adjust the input flow until the lube flow is 140 ± 4 L/min (37 ± 1 US gpm). Maintain this flow during this check.
- Adjust the input rotation to 725 ± 35 rpm.
- Shift the transmission to FORWARD 2.
- Adjust the input rotation to 2000 ± 30 rpm.
- The transmission lubrication pressure must be within ± 7 kPa (± 1 psi) of the average for this arrangement. Reference is 131 ± 7 kPa (19 ± 1 psi).
- Record the value in Table 11.
Clutch Leakage Check
- Adjust the input flow to 201 ± 4 L/min (53 ± 1 US gpm). Maintain this flow during this check.
- Adjust the input rotation to 700 ± 35 rpm.
- Shift the transmission to the FORWARD 1 position.
- Adjust the input rotation to 2000 ± 80 rpm.
- Record the input flow in Table 12.
- Record the lube flow in Table 12.
- The leakage is obtained by subtracting the lube flow from the input flow.
- Record the calculation in Table 12.
- Adjust the input rotation to 700 ± 35 rpm.
- Shift the transmission through positions FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, REVERSE 1, REVERSE 2, REVERSE 3, and NEUTRAL. Repeat Steps 4 through 9 for each gear range.
Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.
- The difference in lube flow between SECOND and THIRD gear ranges and between FORWARD and REVERSE shall be no more than 2.3 L/min (0.60 US gpm).
- The difference in lube flow between SECOND and THIRD gear ranges and between FIRST shall be no more than 3.0 L/min (0.80 US gpm) of the average for this arrangement. Reference is 6.1 ± 3.0 L/min (1.60 ± 0.80 US gpm).
- Record the calculations in Table 12.
- Adjust the input rotation to 700 ± 35 rpm.
Contamination Control
- Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 18/15.
- Record the results in Table 13.
- 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 | 2000 ± 80 rpm | 700 ± 35 rpm |
| Input Flow | 201 ± 4 L/min (53 ± 1 US gpm) |
72 ± 4 L/min (19 ± 1 US gpm) |
| Minimum Lube Flow | - | 11 L/min (4 US gpm) |
| Pressures | ||
| "P1" Initial (1) | - | 620 ± 34 kPa (90 ± 5 psi) |
| P1 | 2550 ± 138 kPa (370 ± 20 psi) |
2206 kPa (320 psi) min |
| P2 | P1 − 379 ± 55 kPa (P1 − 55 ± 8 psi) |
P1 − 379 ± 55 kPa (P1 − 55 ± 8 psi) |
| P3 (2) | - | 930 ± 55 kPa (135 ± 8 psi) |
| Lube (Reference) | 172 ± 35 kPa (25 ± 5 psi) |
21 ± 7 kPa (3 ± 1 psi) |
| ( 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. |
Solenoid Test
| Solenoid Test | Solenoid 1 | Solenoid 2 | Solenoid 3 | Solenoid 4 | Solenoid 5 | Solenoid 6 |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
Preliminary Checks
| Transmission Lubrication Pressure | Input Speed (700 ± 35 rpm) Input Flow 72 ± 4 L/min (19 ± 1 US gpm) |
_______kPa _______(psi) |
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Primary Pressure Check
| Initial Pressure | Input Speed (700 ± 35 rpm) Input Flow 72 ± 4 L/min (19 ± 1 US gpm) |
_______kPa _______(psi) |
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Torque Converter Inlet Ratio Valve
| Torque Converter Inlet Ratio Valve | Input Speed (700 ± 35 rpm) Input Flow 72 ± 4 L/min (19 ± 1 US gpm) |
_______kPa _______(psi) |
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Lube Circuit Check
| Lube Circuit Check | Gear Range FORWARD 2 Input Speed (2000 ± 30 rpm) Lube Flow 140 ± 4 L/min (37 ± 1 US gpm) |
||
| Average Transmission Lubrication Pressure Of Arrangement | _______kPa _______(psi) |
Transmission Lubrication Pressure | _______kPa _______(psi) |
Clutch Leakage Check
| Clutch Leakage Check | Input Speed (2000 ± 30 rpm) Input Flow 201 ± 1 L/min (53 ± 1 US gpm) |
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| Gear Range | 1F | 2F | 3F | 4F | 5F | 6F | 1R | 2R | 3R | N |
Input Flow |
______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ |
Lube Flow |
______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ |
Leakage |
______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ |
Contamination Control
| Contamination Control | Sample the test bench oil supply. |
________/________Particle Count |
| ______________________________________ Technician |
______________________________________ Supervisor |