Bench Test Procedure for a R2900G and R3000H Load Haul Dump Transmission {3030, 3030, 3073} Caterpillar

Load Haul Dump

R2900G (S/N: GLK1-UP; JLK1-UP; NLK1-UP)

R3000H (S/N: RCM1-UP; RCY1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS3625
03	Added prefix NLK and arrangement 488-8199. Added prefix RCY and removed arrangement 382-9012. Standardized.
02	Updated Title.
01	Updated Effectivity and added arrangement numbers 382-8140 and 382-9012 to Table 2.

© 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 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 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:

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

• Knowledge Network

Table 2

Machine Model	Transmission Arrangement
R2900G	226-9195, 488-8199
R3000H	382-8140

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

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.

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 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.

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.

Table 3

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)	4
	8T-3282	Hard Washer	4
	1D-4590	Bolt (5/8-11X4.75 inch)	4
	5P-8247	Hard Washer	8
	4K-0367	Full Nut	4
B	4C-4627	Adapter	1
	4L-7124	Bolt (1/2-20X1.25 inch)	4
	3B-4508	Lockwasher	4
C	136-3647	Drive Adapter As	1
	2J-5245	Bolt (3/8-16X1.25 inch)	4
	3B-4506	Lockwasher	4
D	1U-9131	Drive Adapter (KEY)(1)	1
E	1U-9359	Drive Adapter(2)	1
F	1U-9722	Load Binder As (Ratchet Type)	4
	439-3939	Link Bracket As	4
	1A-8063	Bolt (3/4-10X2.5 inch)	4
	5P-8248	Hard Washer	4
G	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
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
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	120-6843	Ball Valve
M	277-2362	Transmission Analyzer Tool Gp	1
	9U-7498	Adapter Cable As (Transmission Analyzer)	1
	459-4084	Adapter Cable As	1
N	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	2
	6V-4144	Coupler	2
P	8T-0854	Pressure Gauge (0 to 1,000 kPa (0 to 140 psi))	1
	6V-4144	Coupler	1
R	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

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Illustration 3	g02751541

1. Install Tooling (A), to the test stand.
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   Illustration 4	g02751216

2. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1451 kg (3200 lb).
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   Illustration 5	g02751697

3. Install Tooling (B) to the input yoke.
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   Illustration 6	g02751756

4. Install Tooling (C) to Tooling (B).
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   Illustration 7	g02751857

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 (E) on Tooling (D).

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   Illustration 8	g02751879

6. Align the transmission with the input drive shaft.

7. Connect the input drive shaft to Tooling (D).
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   Illustration 9	g02751919

8. Install the drive shaft guard.
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   Illustration 10	g03375318

9. Tighten all four castle nuts and jack bolts.
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   Illustration 11	g02753280

10. Install Tooling (F) to the input and output ends of the transmission.
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    Illustration 12	g02755939

11. Remove cover plate (1).
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    Illustration 13	g02753559

12. Remove filter assembly (2).
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    Illustration 14	g02753436

13. Remove drain plug (3).
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    Illustration 15	g02756216

14. Install Tooling (G).
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    Illustration 16	g02756259

15. Install Tooling (H).
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    Illustration 17	g02755241

16. Remove Plug (4) and Cover Plate (5).
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    Illustration 18	g02755337

17. Install Tooling (J).
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    Illustration 19	g02755376

18. Install Tooling (K).
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    Illustration 20	g02755477
    (6) Converter Inlet Oil

19. Connect hose assembly (6) from Tooling (H) to the No. 2 flow meter inlet.

    Note: The No. 2 flow meter will measure the converter inlet oil that is returning to the test bench.

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    Illustration 21	g02755517
    (7) Supply Oil

20. Connect hose assembly (7) 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 22	g02756056
    (8) Lube Oil (L) Ball Valve

21. Connect hose assembly (8) from the No. 2 flow meter outlet to Tooling (L).
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    Illustration 23	g02756381
    (9) 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.

22. Connect a pressure gauge to pressure tap (9).
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    Illustration 24	g02753381
    (10) Transmission Lubrication

23. Connect a pressure gauge to pressure tap (10) to Tooling (K).
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    Illustration 25	g02756437

24. Connect Tooling (M) to the transmission.
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    Illustration 26	g02753176

25. Connect Tooling (M) to a suitable location.
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    Illustration 27	g02629190
    Tooling (M)

26. Connect Tooling (M) to a power source. Refer to Tool Operating Manual, NEHS0966 for the correct operating instructions.

Test Procedure

TA3 Navigation

1. Select “Load Haul Dump”.

2. Select “R2900-24V”.

Harness Test

1. Make sure that the harness is properly connected.

2. Use Tooling (M) to perform the harness test.

3. Record the values in Table 6.

   Note: Do not continue testing until Harness Test passes.

Start Checks

Note: Refer to Testing and Adjusting, RENR7807, "R2900G Load Haul Dump 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 74 ± 4 L/min (19 ± 1 US gpm).
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   Illustration 28	g02720621

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 725 ± 35 rpm.

4. Shift the transmission through all gears to eliminate air from the transmission controls.

5. The reference for the lube pressure is 21 ± 7 kPa (3 ± 1 psi).

   Note: The input shaft will be rotated in a counterclockwise direction for the duration of this test. The direction is determined as you face the drive motor of the test bench.

6. Record the value in Table 8.

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
   N			X
   F1		X				X
   F2		X			X
   F3		X		X
   F4		X	X
   R1	X					X
   R2	X				X
   R3	X			X
   R4	X		X

8. Stop the input rotation.

9. Stop the input flow.

Initial Pressure Check

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Illustration 29	g02752957

1. Remove cover (11).
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   Illustration 30	g02753057
   (12) Direction Clutch Pressure "P2" (13) Speed Clutch Pressure "P1"

2. Connect pressure gauges to pressure taps (12) and (13).
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   Illustration 31	g02755581
   Load piston plug removed.

3. Remove load piston plug (14).
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   Illustration 32	g02758517
   (15) P3 Pressure Tap for the converter inlet oil pressure.

4. Connect pressure gauge to pressure tap (15).
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   Illustration 33	g02752937

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

6. Adjust the input flow to 74 ± 4 L/min (19 ± 1 US gpm).

7. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 725 ± 35 rpm.

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

9. Record the value in Table 9.

10. Stop the input rotation.

11. Stop the input flow.

12. Install load piston (14).

Torque Converter Inlet Ratio Valve

1. Adjust the input flow to 74 ± 4 L/min (19 ± 1 US gpm). Maintain this flow during this check.

2. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 725 ± 35 rpm.

3. Shift the transmission to FORWARD 1.

4. Use Tooling (L) to momentarily block the lube flow.

5. The converter inlet pressure must be 951 ± 55 kPa (138 ± 8 psi).

6. Open the lube flow.

7. Record the value in Table 10.

Lube Circuit Check

1. Adjust the input flow until the lube flow is 152 ± 4 L/min (40 ± 1 US gpm). Maintain this flow during this check.

2. Adjust the input rotation to 725 ± 35 rpm.

3. Shift the transmission to FORWARD 3.

4. Adjust the input rotation to 1500 ± 30 rpm.

5. The lube pressure must be within ± 14 kPa (± 2 psi) of the average for this arrangement. Reference is 117 ± 14 kPa (17 ± 2 psi). Refer to "Collecting the Test Data" in this document.

6. Record the value in Table 11.

Clutch Leakage Check

1. Adjust the input flow to 152 ± 4 L/min (40 ± 1 US gpm). Maintain this flow during this check.

2. Adjust the input rotation to 700 ± 35 rpm.

3. Shift the transmission to the FORWARD 1 position.

4. Adjust the input rotation to 2000 ± 80 rpm.

5. Record the input flow in Table 12.

6. Record the lube flow in Table 12.

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

8. Record the calculation in Table 12.

9. Adjust the input rotation to 700 ± 35 rpm.

10. 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 and REVERSE.

11. 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).

12. The difference in lube flow between SECOND and FIRST, THIRD, and FOURTH gear ranges must not exceed 3 L/min (0.8 US gpm) of the average for this arrangement. Reference is 4.5 ± 3 L/min (1.2 ± 0.8 US gpm). Refer to "Collecting the Test Data" in this document.

13. Record the calculations in Table 12.

14. Adjust the input rotation to 700 ± 35 rpm.

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 13.

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

Transmission Bench Test Data Sheet

Table 5

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

Harness Test

Table 6

Harness Test	Solenoid 1	Solenoid 2	Solenoid 3	Solenoid 4	Solenoid 5
	_______ ohms	_______ ohms	_______ ohms	_______ ohms	_______ ohms

Specifications

Table 7

Specifications
Description	High Idle	Low Idle
Input Speed	2000 ± 30 rpm	725 ± 35 rpm
Input Flow	202 ± 4 L/min (53 ± 1 US gpm)	74 ± 2 L/min (19 ± 1 US gpm)
Minimum Lube Flow	-	6 ± 3 L/min (2 ± 1 US gpm)
Pressures
"P1" Initial(1)	-	531 ± 34 kPa (77 ± 5 psi)
P1	2551 ± 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)	-	522 ± 30 L/min (138 ± 8 US gpm)

(1)	The load piston plug is removed and the transmission is in the NEUTRAL position.
(2)	The flow for the converter outlet is restricted.

Start Checks

Table 8

Lube Pressure

Input Speed (725 ± 35 rpm) Input Flow 74 ± 2 L/min (19 ± 1 US gpm)

_______kPa _______(psi)

Primary Pressure Check

Table 9

Initial Pressure

Input Speed (725 ± 35 rpm) Input Flow 74 ± 2 L/min (19 ± 1 US gpm)

_______kPa _______(psi)

Torque Converter Inlet Ratio Valve

Table 10

Torque Converter Inlet Ratio Valve

Input Speed (725 ± 35 rpm) Input Flow 74 ± 2 L/min (19 ± 1 US gpm)

_______kPa _______(psi)

Lube Circuit Check

Table 11

Lube Circuit Check		Gear Range FORWARD 3 Input Speed (1500 ± 30 rpm) Lube Flow 152 ± 4 L/min (40 ± 1 US gpm)
Average Lube Pressure Of Arrangement	_______kPa _______(psi)	Lube Pressure	_______kPa _______(psi)

Clutch Leakage Check

Table 12

Clutch Leakage Check			Input Speed (2000 ± 30 rpm) Input Flow 152 ± 4 L/min (40 ± 1 US gpm)
Gear Range	N	F1	F2	F3	F4	R1	R2	R3	R4
Input Flow	______	______	______	______	______	______	______	______	______
Lube Flow	______	______	______	______	______	______	______	______	______
Leakage	______	______	______	______	______	______	______	______	______

Contamination Control

Table 13

ISO Particle Count

Sample the test bench oil supply. *ISO 4406

________/________Particle Count

Table 14

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