Bench Test Procedure for a 24M Motor Grader Transmission{3030, 3073, 3139} Caterpillar

Motor Grader:

24M (S/N: B9K1-UP)

Introduction

© 2014 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar 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 a specific transmission arrangement. 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. Testing 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 need, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

• Cat Dealer Techinical Communicator

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Collecting the Test Data

Since conditions vary for each test bench, it is important to 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.

Illustration 1	g02139237

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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 not 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.

Installation Procedure

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Illustration 2	g02646146

1. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1504 kg (3315 lb).

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Illustration 3	g02625237

2. Install Tooling (A) to the output end of the transmission, as shown.

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Illustration 4	g02646393

3. Install Tooling (B) to the input yoke.

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Illustration 5	g02646589

4. Install Tooling (C) to Tooling (B) .

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Illustration 6	g02646627

5. Install Tooling (D) to Tooling (C) .

   Note: Tooling (D) will adapt to the small drive shaft. If you are using the large drive shaft, install Tooling (M) on Tooling (D) .

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Illustration 7	g02646666

6. Align the transmission with the input drive shaft.

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

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Illustration 8	g02646677

8. Install Tooling (E) at the input and output ends of the transmission.

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Illustration 9	g02646693

9. Remove filter assembly (1) .

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Illustration 10	g02646710

10. Remove drain plug (2) .

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Illustration 11	g02622026

11. Install Tooling (F) .

    Note: Tooling (F) will activate the drain valve. This will allow the oil to drain into the test bench.

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Illustration 12	g02646722

12. Install Tooling (G) .

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Illustration 13	g02646739

13. Install Tooling (H) .

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14. Install Tooling (J) .

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Illustration 15	g02647142
(3) Supply Oil

15. Connect hose assembly (3) from the pressurized flow meter to Tooling (G) .

    Note: The flow meter will measure the flow of the supply oil.

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Illustration 16	g02647152
(4) Controls (out)

16. Connect hose assembly (4) from Tooling (H) to the No. 2 flow meter inlet.

    Note: In the machine, this flow would be torque converter inlet flow.

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Illustration 17	g02647243
(5) Lube (in)

17. Connect hose assembly (5) from the outlet of the No. 2 flow meter to Tooling (F) .

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Illustration 18	g02647250
(6) 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.

18. Connect a pressure gauge to pressure tap (6) .

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Illustration 19	g03698511
(7) Lube (in)

19. Connect a pressure gauge to pressure tap (7) .

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Illustration 20	g03698520

20. Remove plug (8) from transmission body.

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Illustration 21	g03698524
(9) No. 1 clutch (10) No. 2 clutch (11) No. 3 clutch (12) No. 4 clutch (13) No. 5 clutch (14) No. 6 clutch

21. Connect a pressure gauge to taps (9), (10), (11), (12), (13), and (14) as shown.

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

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Illustration 22	g02646021

22. Connect Tooling (K) to the transmission.

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Illustration 23	g01014281

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

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Illustration 24	g02622102
Tooling (K)

24. Connect Tooling (K) to a power source. Refer to Tool Operating Manual, NEHS0996 for the correct operating instructions.

Test Procedure

Solenoid Test

1. Make sure that the harness is properly connected.

2. Use Tooling (K) to perform the solenoid test.

3. Record the values in Table 6.

Preliminary Checks

Note: Refer to Testing and Adjusting, RENR8489, "24M Motor Grader 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.

2. Adjust the input flow to 90.8 ± 3.8 L/min (24 ± 1 US gpm).

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Illustration 25	g02720621

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 800 ± 10 rpm.

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

5. Shift the transmission until all clutch fills are consistent.

6. The lubrication pressure must be between minimum 21 ± 10 kPa (3 ± 1.5 psi).

7. Record the value in Table 7.

8. Stop the input rotation.

9. Stop the input flow.

Lube Circuit Check

1. Adjust the input flow until the lube flow is 140 ± 1.9 L/min (37.0 ± 0.5 US gpm). Maintain this flow during this check.

2. Adjust the input rotation to 800 ± 10 rpm.

3. Shift the transmission to FORWARD 2.

4. Adjust the input rotation to 2000 ± 20 rpm.

5. The lubrication pressure must be 142 ± 14 kPa (20.6 ± 2.0 psi).

6. Record the value in Table 8.

Clutch Leakage Check

1. Adjust the supply flow to 201 ± 11 L/min (53 ± 3 US gpm). Maintain this flow during this check.

2. The supply pressure should be 2172 ± 69 kPa (315 ± 10 psi).

3. Adjust the input rotation to 800 ± 10 rpm.

4. Shift the transmission to the FORWARD 1 position.

5. Adjust the input rotation to 2000 ± 20 rpm.

6. Record the input flow in Table 9.

7. Record the lube flow in Table 9.

8. The leakage is obtained by subtracting the lube flow from the input flow.

9. Record the calculation in Table 9.

10. Adjust the input rotation to 800 ± 10 rpm.

11. Shift the transmission through positions FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, REVERSE 3, REVERSE 2, REVERSE 1, and NEUTRAL. Repeat Steps 4 through 10 for each gear range.

12. The difference in lube flow between SECOND and THIRD gears in the same direction, and between FORWARD and REVERSE in the same range should be no more than 2.3 L/min (0.6 US gpm).

13. The leakage between SECOND, THIRD, and FIRST should not exceed 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).

Contamination Control

1. Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 18/15.

2. Record the results in Table 10.

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

Specifications

Transmission Bench Test Data Sheet

Solenoid Test

Preliminary Checks

Lube Circuit Check

Clutch Leakage Check

ISO Particle Count