Bench Test Procedure for a 824G Wheel Dozer, 824G Series 2 Wheel Dozer, 825G Soil Compactor, 825G Series 2 Soil Compactor, and 826G Landfill Compactor, and 826G Series 2 Landfill Compactor Transmission {3030, 3073} Caterpillar

Landfill Compactor

826G (S/N: 7LN1-UP)

826G Series II (S/N: AYH1-UP)

Soil Compactor

825G (S/N: 6RN1-UP)

825G Series II (S/N: AXB1-UP)

Wheel Dozer

824G (S/N: 4SN1-UP)

824G Series II (S/N: AWW1-UP)

Introduction

© 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 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

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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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.

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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 this transmission test. 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.

Installation Procedure

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1. Install Tooling (A) to the test stand.
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2. Use a hoist to install the transmission onto Tooling (A). The weight of the transmission is 838 kg (1850 lb).
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3. Install Tooling (B) on the torque converter.
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4. Install Tooling (C) to the transmission case.
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   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.

5. Install Tooling (D) on Tooling (C).
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6. Tighten the collet on Tooling (D) to connect Tooling (D) to Tooling (B).
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7. Install Tooling (E) to the input shaft of Tooling (D).
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8. 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).

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9. Align the transmission with the input drive shaft.

10. Connect the input drive shaft to Tooling (F).
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11. Install the drive shaft guard.
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12. Tighten all four castle nuts and jack bolts.
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13. Install Tooling (H) to the output end of the transmission.
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14. Install Tooling (H) to the input end of the transmission.
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15. Remove cover plate (1).
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16. Remove filter assembly (2).
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17. Remove drain plug (3).
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18. Install Tooling (J).

    Note: Tooling (J) will activate the drain valve, and will allow the oil to drain into the test bench.

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    Illustration 21	g02765758

19. Install Tooling (K).
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20. Install Tooling (L).

21. Install Tooling (U) to Tooling (L).

    Note: Picture not shown.

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    Illustration 23	g02765816

22. Install Tooling (M).
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23. Install Tooling (N).
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24. Install Tooling (N).
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    Illustration 26	g00888478

25. Remove cover (4).
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    Illustration 27	g00888479
    (5) Supply Oil

26. Connect hose assembly (5) from the pressurized flow meter to Tooling (K).

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

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    Illustration 28	g00888480
    (6) Converter Outlet Oil

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

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

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    Illustration 29	g00888481
    (7) Lube Oil

28. Connect hose assembly (7) from the No. 2 flow meter outlet to Tooling (M).
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    Illustration 30	g00888482
    (8) Direction Clutch Pressure "P2" (9) Speed Clutch Pressure "P1"

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

29. Connect a pressure gauge to pressure tap (8).

30. Connect a pressure gauge to pressure tap (9).
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    (10) Converter Inlet Pressure "P3"

31. Connect a pressure gauge to pressure tap (10).
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    (11) Converter Outlet Pressure

32. Connect a pressure gauge to pressure tap (11).
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    Illustration 33	g00888486
    (12) Transmission Lubrication Pressure

33. Connect a pressure gauge to pressure tap (12).
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34. Connect Tooling (P) to the transmission.
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35. Connect Tooling (P) to a suitable location.
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    Illustration 36	g01014114

36. Connect lube line (13) from the test bench to Tooling (D). Maintain an oil pressure of 275 kPa (40 psi).
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    Illustration 37	g00888852

37. Cover the transmission. Use a suitable clean cover.
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    Illustration 38	g00877510
    Tooling (P)

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    Tooling (P)

38. Connect Tooling (P) 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.

Test Procedure

TA3 Navigation

1. Select “Compactors”.

2. Select “825G-24V” or “826G-24V”.

Harness Test (TA3 only)

1. Make sure that the harness is properly connected.

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

3. Record the values in Table 7.

   Note: Do not continue testing until Harness Test passes.

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 7.

   Note: Do not continue testing until Solenoid Test passes.

Start Checks

Note: Refer to Testing and Adjusting, SENR1328, "824G Wheel Dozer, 825G Soil Compactor, and 826G Landfill Compactor Power Train" or Testing and Adjusting, RENR6028, "824G Series 2 Wheel Dozer, 825G Series 2 Soil Compactor, and 826G Series 2 Landfill Compactor 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 64 ± 4 L/min (16 ± 1 US gpm).
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3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 30 rpm.

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

5. The lube pressure should be 14 ± 14 kPa (2 ± 2 psi).

   Note: If there is no lube pressure after 3 seconds, stop input rotation and check connections on test bench and transmission.

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.

Primary Pressure Check

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1. Remove plug (13).
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   Illustration 42	g00888899

2. Install a 5/16-18 bolt into the end of load piston plug (14).

3. Remove load piston plug (14).

4. Install plug (13).

5. Adjust the input flow to 64 ± 4 L/min (16 ± 1 US gpm).

6. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 30 rpm.

7. The "P1" pressure must be 531 ± 34 kPa (77 ± 5 psi).

8. Record the value in Table 9.

9. Stop the input rotation.

10. Stop the input flow.

11. Install load piston plug (14).

Converter Inlet Ratio Valve

1. Adjust the input flow to 64 ± 4 L/min (16 ± 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 700 ± 30 rpm.

3. Shift the transmission to FORWARD 1.

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

5. The converter inlet pressure must be 910 ± 55 kPa (132 ± 8 psi).

6. Open Tooling (U).

7. Record the value in Table 10.

Lube Circuit Check

1. Adjust the input flow until the lube flow is 95 ± 4 L/min (25 ± 1 US gpm). Maintain this flow during this check.

2. Adjust the input rotation to 700 ± 30 rpm.

3. Shift the transmission to FORWARD 3.

4. Adjust the input rotation to 1750 ± 30 rpm.

5. The lube pressure should be 76 ± 14 kPa (11 ± 2 psi).

6. Record the value in Table 11.

Clutch Leakage Check

1. Adjust the input flow to 178 ± 4 L/min (47 ± 1 US gpm). Maintain this flow during this check.

2. Adjust the input rotation to 700 ± 30 rpm.

3. Shift the transmission to the FORWARD 1 position.

4. Adjust the input rotation to 2100 ± 30 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 ± 30 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 leakage for FIRST, THIRD, and FOURTH gear ranges in FORWARD and REVERSE should be 30.3 ± 5.7 L/min (8 ± 1.5 US gpm).

12. The leakage for FORWARD 2 and REVERSE 2 gear ranges should be 34 ± 5.7 L/min (9 ± 1.5 US gpm).

13. The difference in leakage between the FIRST, THIRD, and FOURTH gear ranges or between FORWARD and REVERSE shall be no more than 2.3 L/min (0.6 US gpm).

14. The leakage between SECOND and FIRST, THIRD, and FOURTH must not exceed 3 L/min (0.8 US gpm) of the average for the test bench for this arrangement. Reference is 5.3 ± 3 L/min (1.4 ± 0.8 US gpm).

15. Record the calculations in Table 12.

16. Adjust the input rotation to 700 ± 30 rpm.

Contamination Control

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

2. Record the results in Table 21.

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

Transmission Bench Test Data Sheet

Specifications

Solenoid Test

Start Checks

Primary Pressure Check

Torque Converter Inlet Ratio Valve

Lube Circuit Check

Clutch Leakage Check

Contamination Control