Bench Test Procedure for a 120H, 12H, 135H, 140H, 143H, 160H, and 163H Motor Grader Transmission {3030, 3073} Caterpillar

Motor Grader

120H (S/N: 4MK1-UP; 5FM1-UP; 6NM1-UP; 6TM1-UP; 2AN1-UP; 6YN1-UP; 9FN1-UP; 3GR1-UP)

12H (S/N: 4XM1-UP; 5ZM1-UP; 8MN1-UP; 2LR1-UP; 2WR1-UP; 4ER1-UP; 2GS1-UP)

135H (S/N: 3YK1-UP; 8WN1-UP)

140H (S/N: 2ZK1-UP; 5HM1-UP; 8JM1-UP; 8KM1-UP; 9TN1-UP; 9ZN1-UP; 3FR1-UP; 3AS1-UP)

143H (S/N: 1AL1-UP)

160H (S/N: 9EJ1-UP; 2FM1-UP; 3GM1-UP; 6WM1-UP; 9JM1-UP; 3HR1-UP; 2HS1-UP)

163H (S/N: 5AK1-UP)

Introduction

© 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 technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

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 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.

Required Tools

Installation Procedure

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Illustration 3	g00950587

1. Use a hoist to move the transmission to the test bench. The weight of the transmission is 840 kg (1851 lb).

2. Install Tooling (A) to the transmission, as shown.
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   Illustration 4	g00950588

3. Use a hoist to install the transmission on the test bench.
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   Illustration 5	g00950589

4. Install Tooling (B) on the transmission.
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   Illustration 6	g00950590

5. Install Tooling (C) on Tooling (B).
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   Illustration 7	g00950591

6. Align the transmission with the input drive shaft.

7. Connect the input drive shaft to Tooling (C).
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   Illustration 8	g00950592

8. Install the drive shaft guard.
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   Illustration 9	g03802221

9. Tighten the castle nuts and jack bolts, four locations.
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   Illustration 10	g00950593

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   Illustration 11	g00950618

10. Install Tooling (D) to the transmission.
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    Illustration 12	g00950597

11. Install Tooling (E) on the transmission pump.
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    Illustration 13	g00950598

12. Install Tooling (F) on the transmission pump.
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    Illustration 14	g00950599

13. Install Tooling (G) on the transmission pump.
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    Illustration 15	g00950600

14. Install Tooling (H) on the transmission.
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    Illustration 16	g01833354

15. Install Tooling (J) on the transmission.
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    Illustration 17	g01833382

16. Install Tooling (K) on the transmission.
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    Illustration 18	g01833415

17. Install Tooling (L) on the parking brake.
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    Illustration 19	g03681418

18. Connect hose assembly (1) to Tooling (F).
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    Illustration 20	g03681425

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

    Note: The No. 1 flow meter will measure the pump supply flow.

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    Illustration 21	g03681438

20. Connect hose assembly (3) from No. 1 flow meter outlet to Tooling (H).
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    Illustration 22	g03681442

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

    Note: The No. 2 flow meter will measure the oil cooler flow.

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    Illustration 23	g03681444

22. Connect hose assembly (5) from No. 2 flow meter outlet to Tooling (J).
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    Illustration 24	g03681448

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

23. Connect a pressure gauge to pressure tap (6).
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    Illustration 25	g03681455

24. Connect a pressure gauge to pressure tap (7).
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    Illustration 26	g00950611
    (10) Pressure tap for No. 3-A clutch (11) Pressure tap for No. 4-E clutch (12) Pressure tap for No. 1-B clutch (13) Pressure tap for No. 6-F clutch (14) Pressure tap for No. 2-C clutch (15) Pressure tap for No. 5-G clutch (16) Pressure tap for No. 8-D clutch (17) Pressure tap for No. 7-H clutch

25. Connect eight pressure gauges to the clutch pressure taps (10), (11), (12), (13), (14), (15), (16), and (17).
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    Illustration 27	g00950612

26. Connect air supply hose (18) to Tooling (L). Maintain a minimum 552 kPa (80 psi) air supply.
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    Illustration 28	g01833435

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    Illustration 29	g00950614
    (19) Cable connector "4-E" for No. 4 clutch solenoid (20) Cable connector "3-A" for No. 3 clutch solenoid (21) Cable connector "6-F" for No. 6 clutch solenoid (22) Cable connector "1-B" for No. 1 clutch solenoid (23) Cable connector "5-G" for No. 5 clutch solenoid (24) Cable connector "2-C" for No. 2 clutch solenoid (25) Cable connector "7-H" for No. 7 clutch solenoid (26) Cable connector "8-D" for No. 8 clutch solenoid

27. Connect Tooling (M) to eight clutch solenoids, as shown.
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    Illustration 30	g00877510
    Tooling (P)

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    Illustration 31	g03719421
    Tooling (P)

28. Connect Tooling (P) to a power source. Refer to Tool Operating Manual, NEHS0644 or Tool Operating Manual, NEHS0996 for the correct operating instructions.
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    Illustration 32	g00950615

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

Test Procedure

TA2 Navigation

The 9U-7500 Electronic Control Group has been programmed to ensure that the transmission will be shifted sequentially through the gears. The functionality of some of the input keys has been changed to ensure the requirements of this procedure. The following examples are typical screen displays.

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Illustration 33	g00950917

1. Select "MOTOR GRADERS" from the main menu.
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   Illustration 34	g00950918

2. Select "XXXH-LE" for the correct transmission.
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   Illustration 35	g00950921

3. Select the correct test program.

   Note: The available keys will be listed across the bottom of the active display screen.

Illustration 36	g00950907

Forward - Use the "FWD" key to shift the transmission to FORWARD 1.

Reverse - Use the "REV" key to shift the transmission to REVERSE 1.

Illustration 37	g00950909

Illustration 38	g00950910

Neutral - Use the "N" key to shift the transmission to NEUTRAL.

Upshift - Use the "UP CURSOR" key to upshift the transmission to the next higher gear range.

Illustration 39	g00950911

Downshift - Use the "DOWN CURSOR" key to downshift the transmission to the next lower gear range.

TA3 Navigation

1. Select “Motor Graders”.

2. Select either “120H-24V”, “12H-24V”, “135H-24V”, “140H-24V”, “143H-24V”, “160H-24V”, or “163H-24V”.

Solenoid Test (TA2 Only)

1. Make sure that the harness is properly connected.

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

3. Record the values in Table 8.

Harness Test (TA3 Only)

1. Make sure that the harness is properly connected.

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

3. Record the values in Table 8.

Start Checks

Note: Refer to Testing and Adjusting, RENR4104, "120H, 12H, 135H, 140H, 143H, 160H, and 163H Motor Graders Power Train" for the correct adjusting procedures.

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NOTICE
The existing valve 161-7055 Valve Body could crack in the rib area on certain 12H, 120H, 135H, 140H, 143H, 160H, and 163H Motor Graders. If the existing valve body fails, it will cause a loss of Clutch H-7 pressure. Refer to Service Letter, REBE8618, "PRODUCT SUPPORT PROGRAM FOR REPLACING THE 161-7055 VALVE BODY ON CERTAIN 12H, 120H, 135H, 140H, 143H, 160H, AND 163H MOTOR GRADERS" and the note below.

Note: Reference Service Magazine, SEPD0936, "The Transmission Control Group Has Been Improved". If Clutch H-7 valve spring has been changed, pressure will be 2813 ± 83 kPa (408 ± 12 psi)

1. If you are using SAE10W oil, warm the oil to 50 °C (125 °F). If you are using MobilDTE11 oil, warm the oil to 34 °C (95 °F). Maintain this temperature for the duration of the test.

2. Set the input flow to 102 ± 4 L/min (27 ± 1 US gpm).
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   Illustration 40	g02720621

3. Rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 800 ± 25 rpm.

   Note: If there is no lube pressure after 30 seconds, stop the test and verify test stand and transmission connections.

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

5. Verify that the active clutches are correct for each gear range. Refer to Table 4.
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   Table 4

   Transmission Clutch Assignments
   	Direction			Speed			Range
   	Fwd, High	Fwd, Low	Rev	2nd	3rd	1st	Low	High
   	1	2	3	4	5	6	7	8
   N					X			X
   1F	X					X	X
   2F		X		X			X
   3F		X			X		X
   4F	X				X		X
   5F	X					X		X
   6F		X		X				X
   7F	X			X				X
   8F	X				X			X
   1R			X			X	X
   2R			X	X			X
   3R			X		X		X
   4R			X			X		X
   5R			X	X				X
   6R			X		X			X

6. With the transmission in NEUTRAL, adjust the input rotation to 2000 ± 25 rpm. Hold until the lubrication pressure rises to 310 ± 34 kPa (45 ± 5 psi).

7. Measure Pump Flow, Lube flow, Pump pressure, and Lube pressure, and all Clutch pressures.

8. Record the values in Table 10.

9. Verify all test points with the values in Table 9.

10. Shift the transmission through all FORWARD gears and measure Lube pressure.

    Note: Remember to reduce input speed down to 800 ± 25 rpm when shifting gears.

11. Record the values in Table 10.

12. Verify all test points with the values in Table 9.

Initial Pressure Check and Adjustment Procedure

1. On the transmission control valve, remove the 8E-9474 Cover and install Tooling (N). Tighten the bolts to 30 ± 4 N·m (22 ± 3 lb ft).

2. Adjust the input speed to 2000 rpm. Shift through speed ranges REVERSE 1, NEUTRAL, FORWARD 1, and FORWARD 2.

   Note: Remember to reduce input speed down to 800 ± 25 rpm when shifting gears.

3. Record Clutch pressures in Table 12.

4. Confirm Clutch pressures with Table 11

   Note: Refer to Illustration 26 for pressure tap port locations.

5. If the pressure does not agree with the specifications in Table 11, adjust the pressure using the following procedure.
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   Illustration 41	g03812405
   (27) 4M-1751 Spacer and 5J-1036 Shim (28) Adjuster Assembly (29) Locknut (30) Adjustment screw

   1. Loosen the locknut (29) on adjuster assembly (28).

   2. While monitoring the pressure, adjust by turning adjustment screw (30). To lower the pressure, turn the adjustment screw clockwise. Total adjustment screw range is approximately 131 kPa (19 psi).

   3. Tighten locknut (29) to 25 ± 4 N·m (18 ± 3 lb ft).

   4. Shift transmission to NEUTRAL for a minimum of 15 seconds then shift the transmission back to the gears above.

   5. Confirm that the pressure agrees with the values in Table 11.

   6. If the pressures cannot be adjusted within the acceptable limits with adjusting screw (30), stop rotation and remove the solenoid manifold to access the selector spool. Remove the selector spool and add or remove shims and spacers as required.
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      Table 5

      Shim Specifications
      5J-1036 Shim
      Outside Diameter	15.09 ± 0.25 mm (0.594 ± 0.01 inch)
      Thickness	0.80 mm (0.031 inch)
      4M-1751 Spacer
      Outside Diameter	15.09 ± 0.25 mm (0.594 ± 0.01 inch)
      Thickness	0.4 mm (0.02 inch)

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      Table 6

      Pressure Specifications For Adding Shims
      Pressure Tap-Clutch	Change in Pressure for One 5J-1036 Shim	Change in Pressure for One 4M-1751 Spacer
      A-3	90 kPa (13 psi)	41 kPa (6 psi)
      B-1	90 kPa (13 psi)	41 kPa (6 psi)
      C-2	97 kPa (14 psi)	48 kPa (7 psi)
      D-8	110 kPa (16 psi)	55 kPa (8 psi)
      E-4	76 kPa (11 psi)	41 kPa (6 psi)
      F-6	110 kPa (16 psi)	55 kPa (8 psi)
      G-5	117 kPa (17 psi)	55 kPa (8 psi)
      H-7	62 kPa (9 psi)	28 kPa (4 psi)

   7. Install the solenoid manifold, and adjust the initial pressure according to Steps 5.a through 5.e.

6. Continue the procedure until all the stations (pressure taps) are checked and adjusted.

7. Stop rotation.

8. Remove Tooling (N) and install original 8E-9474 Cover.

9. Use new 9P-9150 Washers and tighten the mounting bolts to 30 ± 4 N·m (22 ± 3 lb ft).

10. To verify clutch pressures, adjust input speed to 2000 rpm and shift through gears REVERSE 1, NEUTRAL, FORWARD 1, and FORWARD 2.

    Note: Always reduce input speed to low idle when shifting between gears.

    Note: If the transmission clutch pressure (steady state) is out of range, the most likely cause of the failure will be a failed modulating spring, debris in control valve, or seal failure within the transmission.

Inching Test

1. Adjust the input speed to 800 ± 25 rpm.

2. Check to make sure the modulation switches open at the required pressure setting.

   1. Place the transmission in FORWARD 1 and the manual modulation plunger in the full pressure position. The 111-7088 Pressure Switch and 3E-7811 Pressure Switch (if applicable) should be closed. Follow the remaining steps.

   2. Slowly move the manual modulation plunger toward the reduced pressure position.

   3. Before the pressure at station "B" reaches 120 kPa (17 psi), the 3E-7811 Pressure Switch (if applicable) must open.

   4. Before the pressure at station "B" reaches 50 kPa (7 psi), the 111-7088 Pressure Switch must open.

   5. When the manual modulation plunger reaches the reduced pressure position, the pressure at station "B" must drop to 14 ± 14 kPa (2 ± 2 psi) and the output speed must drop to 0 rpm within 13 seconds.

3. Check to make sure the modulation switches close at the required pressure setting.

   1. Slowly move the manual modulation plunger towards the full pressure position.

   2. Before the pressure at station "B" reaches 160 ± 20 kPa (23 ± 3 psi), the 3E-7811 Pressure Switch (if applicable) must close.

   3. Before the pressure at station "B" reaches 76 kPa (11 psi), the 111-7088 Pressure Switch must close.

   4. As the plunger continues to move toward the full pressure position, the pressure at station "B" must rise gradually to 758 ± 48 kPa (110 ± 7 psi) and then rise automatically to 2179 ± 97 kPa (316 ± 14 psi)

Lube Circuit Check

1. Shift the transmission to FORWARD 1.

2. Adjust input rotation to produce a Lube flow of 70 L/min (18 US gpm).

3. Lube pressure should be 90 ± 14 kPa (13 ± 2 psi).

4. Record value in Table 13.

ISOParticle Count

1. Sample the test bench oil supply.

2. Record the particle count in Table 14.

Transmission Bench Test Data Sheet

Solenoid/Harness Test

Start Checks

Initial Pressure Checks and Adjustment Procedure

Lube Circuit Check

ISOParticle Count