Bench Test Procedure For A 14H and 16H Motor Grader Transmission{3030, 3073} Caterpillar

Motor Grader:

14H (S/N: ASE1-UP; 7WJ1-UP)

16H (S/N: 6ZJ1-UP; 3JR1-UP; ATS1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS2124
02	Added serial number 3JR. 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 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 issue, use the following resources in order 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
14H	183-6614, 8E-3028
16H	183-6616, 8E-3030

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 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.

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, 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.

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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 in order to develop this test procedure.

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	FT1279	Stand As	1
B	439-3940	Bracket As	2
	1U-9722	Load Binder As	1
	8S-4735	Bolt (9/16-12 X 2.50 inch)	2
	1A-5405	Bolt (5/8-11 X 5.00 inch)	4
	1D-5118	Nut (5/8-11 inch)	4
	8S-5151	Nut (9/16-12 inch)	2
	8T-4122	Flat Washer (5/8 inch)	4
C	FT-1290	Output Adapter	1
	0S-1569	Bolt (5/8X4.00 inch)	5
	1D-5118	Nut (5/8 inch)	5
	2N-3542	Pipe Elbow (1-1/4 inch)	1
	5L-3785	Straight Pipe (1-1/4 x 2.00 inch)	1
	8T-4122	Flat Washer (5/8 inch)	5
	4P-7891	Straight Pipe (1-1/4 X 3.00 inch)	1
	1U-9875	Quick Disconnect (3.00 inch)	1
D	FT-1289	Drive Adapter	1
E	4C-4336	Drive Adapter	1
	5D-0353	Bolt (3/8-16 X 1.00 inch)	4
F	6V-3965	Quick Nipple (9/16-18 inch)	1
G	6V-3965	Quick Nipple (9/16-13 inch)	1
H	5P-5260	Test Cover	1
	0S-1629	Bolt (1/2-20 X 1.00 inch)	26
J	3B-6552	Pipe Elbow (1/8-27 inch)	1
	6V-4142	Female Nipple (1/8-27 inch)	1
	3B-7282	Straight Pipe (1/8-27 inch)	1
K	3B-6552	Pipe Elbow (1/8-27 inch)	1
	6V-4142	Female Nipple (1/8-27 inch)	1
	3B-7282	Straight Pipe (1/8-27 inch)	1
L	7X-7646	Female Nipple (1- 5/16-12 inch)	1
	004-5703	Reducer Bushing (3/4 -14 X 1.00-11.5 inch)	1
	004-7270	Straight Pipe (3/4-14 inch)	2
	6V-7483	Adapter Fitting (1-1/16-12 X 3/4-14 inch)	1
	4B-5984	Pipe Elbow (3/4-14 inch)	1
M	7X-7646	Female Nipple (1- 5/16-12 inch)	1
	004-5703	Reducer Bushing (3/4 -14 X 1.00-11.5 inch)	1
	004-7270	Straight Pipe (3/4-14 inch)	1
	6V-7483	Adapter Fitting (1-1/16-12 X 3/4-14 inch)	1
N	4C-4665	Transmission Shift Adapter	1
	5F-4899	Bolt (3/8-16 X 5.00 inch)	3
P	8T-0862	Pressure Gauge (-100 to 500 kPa (-15 to 72 psi))	1
	6V-4144	Quick Connect Coupler	1
Q	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	5
	6V-4144	Quick Connect Coupler	5

FT Drawings

Illustration 3	g03842016
FT1290 (1) 8M-4990 O-Ring Seal (2) Bolt (3/8-12x1 1/4) (3) 3B-4506 Lockwasher (4) 1D-4717 Nut (5) 6H-3957 Ball Bearing (6) 1T-0043 Ball Bearing

Illustration 4	g03842034
FT1289 (A) 152.4 mm (6.0 inch) (B) 133.35 mm (5.25 inch) (C) 95.25 mm (3.75 inch) (D) Ø 7.92 mm (0.312 inch) 3/8-16 THD (E) 19.05 mm (0.75 inch) (F) 60.55 mm (2.384 inch) (G) 101.6 mm (4.0 inch) (H) 95.25 mm (3.75 inch) (J) 76.2 mm (3.0 inch) (K) 9.525 mm (0.375 inch) (L) 69.85 mm (2.75 inch) (M) 85.73 mm (3.375 inch) (N) 72.24 mm (2.844 inch)

Illustration 5	g03857016
FT1279

Illustration 6	g03857221
FT1279 (continued) (G) For Schroeder Test Bench (H) For Wolfe and Aidco Test Bench

Illustration 7	g03857235
FT1279 (continued) (J) For Wolfe, Aidco, and Schroeder Test Bench (K) For Wolfe, Aidco, and Schroeder Test Bench (L) For Schroeder Test Bench (M) For Wolfe and Aidco Test Bench

Illustration 8	g03857176
FT1279 (continued) This Support As to be used with Schroeder Test Bench

Illustration 9	g03857282
FT1279 (continued) This Support As to be used with Wolfe and Aidco Test Bench

Illustration 10	g03857568
FT1279 (continued) For Schroeder Test Bench

Illustration 11	g03857589
FT1279 (continued) This Base As to be used with Schroeder Test Bench (AA) 1D-4719 Full Nut (BB) 3B-4508 Lockwasher (CC) Bolt (1/2-13 THD 1.75 IN LG) (DD) 4B-4280 Washer

Illustration 12	g03857682
FT1279 (continued) For Wolfe and Aidco Test Bench

Illustration 13	g03857725
FT1279 (continued) This Base As to be used with Wolfe and Aidco Test Bench (AA) 1D-4719 Full Nut (BB) 3B-4508 Lockwasher (CC) Bolt (1/2-13 THD 1.75 IN LG) (DD) 4B-4280 Washer

Installation Procedure

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Illustration 14	g01082363

1. Install Tooling (A) to the transmission.

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Illustration 15	g01082369

2. Use a hoist to install the transmission on the test bench. The weight of the transmission is 959 kg (2114 lb).

3. Install Tooling (B) to the transmission.

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Illustration 16	g01082371

4. Install Tooling (C) to the transmission.

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Illustration 17	g01082373

5. Install Tooling (D) on the input shaft.

   Note: Install the large drive shaft to Tooling (D). Install Tooling (E) if the small drive shaft is used. This is shown in Step 6.

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Illustration 18	g01082380

6. Install Tooling (E) to Tooling (D) .

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Illustration 19	g01082382

7. Align the transmission to the input drive shaft.

8. Connect the input drive shaft to Tooling (E) .

9. Close and latch drive shaft guard.

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Illustration 20	g03802221

10. Tighten all four castle nuts and jack bolts.

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Illustration 21	g01082388

11. Install Tooling (F) .

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Illustration 22	g03860565

12. Install Tooling (G) .

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Illustration 23	g03860568

13. Install Tooling (H) .

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Illustration 24	g03860600

14. Install Tooling (J) .

15. Install Tooling (K) .

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Illustration 25	g03860613

16. Install Tooling (L) .

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Illustration 26	g03860619

17. Install Tooling (M) .

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Illustration 27	g03860660
Suction Hose

18. Connect Hose Assembly (1) to Tooling (C) .

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Illustration 28	g03860661

19. Connect Hose Assembly (2) from Tooling (M) to the No. 2 flow meter inlet.

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

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Illustration 29	g03860731

20. Connect Hose Assembly (3) from the outlet of the No. 2 flow meter to Tooling (L) .

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Illustration 30	g03860733
Drain Hose

21. Connect hose assembly (4) to Tooling (C) .

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Illustration 31	g03860739
(5) Direction Clutch Pressure "P2"

22. Connect Pressure Gauge (5) to Tooling (K) .

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Illustration 32	g01082426
(6) Transfer Gear Case Lubrication Pressure

23. Connect hose assembly (6) to Tooling (F) .

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Illustration 33	g01082431
Lubrication Oil Pressure

24. Connect pressure hose (7) to Tooling (C) .

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Illustration 34	g03860859
(8) Speed Clutch Pressure "P1"

25. Connect pressure hose (8) to Tooling (J) .

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Illustration 35	g01082437
(9) Transmission Lubrication Pressure

26. Connect Pressure Hose (9) to Tooling (G) .

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Illustration 36	g03860865

27. Install Tooling (N) .

Test Procedure

Preliminary Checks

Note: Refer to Testing and Adjusting, SENR6685, "14H and 16H 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 42.0 L/min (11.0 US gpm).

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Illustration 37	g02720621

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 speed ranges to eliminate air from the transmission controls.

5. The lubrication pressure should be 159 ± 69 kPa (23 ± 10 psi).

   Note: If there is no lube pressure after 30 seconds, stop input rotation and check connections on transmission and test bench.

6. Record the lubrication pressure in Table 6.

7. Stop the input rotation.

Neutralizer Valve

1. Shift the transmission to FORWARD 1.

2. Adjust the input rotation to 700 ± 30 rpm. "P1" must be 2515 kPa (365 psi) minimum and "P2" must be 0 kPa (0 psi).

3. Shift the transmission to NEUTRAL. "P1" must drop to initial pressure and "P2" must remain at 0 kPa (0 psi).

4. Shift the transmission to FORWARD 1. Both "P1" and "P2" must rise to normal operating pressure.

5. Record the values in Table 7.

Manual Modulation

1. Adjust input rotation to 1850 ± 10 rpm.

2. With the transmission in FORWARD 1, disengage manual modulation lever. "P1" must drop to initial pressure and "P2" must drop to 103 kPa (15 psi ) (MAX) in 6 seconds. Output rpm must drop to 0 rpm.

3. Slowly engage manual modulation lever. "P1" must jump to 1688 ± 103 kPa (245 ± 15 psi) and "P2" must rise gradually to 1275 ± 138 kPa (185 ± 20 psi). From this point, "P1" and "P2" must rise automatically to normal operating pressure.

4. Record values in Table 8.

5. Repeat steps 1, 2, and 3 in REVERSE 1.

6. Record values in Table 8.

Lube Circuit Check

1. With the transmission in FORWARD 1, adjust input rotation to obtain a lube flow of 57 ± 4 L/min (15 ± 1 US gpm).

2. Lubrication pressure must be within ± 17 kPa (± 2.5 psi) of the average lubrication pressure of the last 99 transmissions. Reference is 96 ± 21 kPa (14 ± 3 psi).

3. Record the value in Table 9.

High Idle Pressure Check

1. With the transmission in NEUTRAL, adjust the input rotation to 1850 ± 10 rpm.

2. Record the pump pressure, speed clutch pressure "P1", direction clutch pressure "P2", lubrication pressure, and lubrication flow in Table 11.

3. Repeat Step 2 in all forward and reverse ranges.

   Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.

4. Compare the values with the required values in Table 10.

5. Stop the input rotation.

Low Idle Pressure Check

1. With the transmission in NEUTRAL, adjust the input rotation to 700 ± 30 rpm.

2. Record the pump pressure, speed clutch pressure "P1", direction clutch pressure "P2", lubrication pressure, and lubrication flow in Table 13.

3. Repeat Step 2 in all forward and reverse ranges.

   Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.

4. Compare the values with the required values in Table 12.

5. Stop the input rotation.

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 14.

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

Transmission Bench Test Data Sheet

Table 4

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

Specifications

Table 5

General Specifications
Description	High Idle	Low Idle
Input Speed	1850 ± 10 rpm	700 ± 30 rpm
Minimum Lube Flow	114 L/min (30 US gpm)	42 L/min (11.0 US gpm)
Pressures
"P1" Initial (1)	621 ± 34 kPa (90 ± 5 psi)	621 ± 41 kPa (90 ± 6 psi)
"P1"	2859 ± 103 kPa (415 ± 15 psi)	2515 kPa (365 psi ) (MIN)
"P2"	P1 - 414 ± 34 kPa (P1 - 60 ± 5 psi)	P1 - 414 ± 34 kPa (P1 - 60 ± 5 psi)
Lube In Neutral	552 ± 103 kPa (80 ± 15 psi)	159 ± 69 kPa (23 ± 10 psi)
Lube In Gear	386 ± 55 kPa (56 ± 8 psi)	41 ± 21 kPa (6 ± 3 psi)

( 1 )

"P1" pressure with pilot selector in NEUTRAL

Preliminary Checks

Table 6

Transmission Lubrication Pressure

Input Speed (700 ± 30 rpm) Input Flow 42 L/min (11 US gpm)

_______kPa _______(psi)

Neutralizer Valve

Table 7

Neutralizer Valve	Gear Range FORWARD 1 Input Speed (700 ± 30 rpm)	"P1" Pressure	_______kPa _______(psi)
		"P2" Pressure	_______kPa _______(psi)
	Gear Range NEUTRAL Input Speed (700 ± 30 rpm)	"P1" Pressure	_______kPa _______(psi)
		"P2" Pressure	_______kPa _______(psi)
	Gear Range FORWARD 1 Input Speed (700 ± 30 rpm)	"P1" Pressure	_______kPa _______(psi)
		"P2" Pressure	_______kPa _______(psi)

Manual Modulation

Table 8

Manual Modulation	Input Speed (1850 ± 10 rpm)
Gear Range FORWARD 1	Disengaged Manual Modulation Lever	"P1" Pressure	_______kPa _______(psi)
		"P2" Pressure	_______kPa _______(psi)
	Engaged Manual Modulation Lever	"P1" Pressure	_______kPa _______(psi)
		"P2" Pressure	_______kPa _______(psi)
Gear Range REVERSE 1	Disengaged Manual Modulation Lever	"P1" Pressure	_______kPa _______(psi)
		"P2" Pressure	_______kPa _______(psi)
	Engaged Manual Modulation Lever	"P1" Pressure	_______kPa _______(psi)
		"P2" Pressure	_______kPa _______(psi)

Lube Circuit Check

Table 9

Lube Circuit Check

Gear Range FORWARD 1 Lube Flow 57 ± 4 L/min (15 ± 1 US gpm)

_______kPa _______(psi)

High Idle Pressure Check

Table 10

High Idle Pressure Check	Input Speed (1850 ± 10 rpm)
Gear Range	Pump Pressure	Speed Clutch Pressure "P1"	Direction Clutch Pressure "P2"	Lubrication Pressure	Lubrication Flow
N	2861 ± 35 kPa (415 ± 5 psi) Maximum	621 ± 34 kPa (90 ± 5 psi)	0	552 ± 103 kPa (80 ± 15 psi)	113.7 L/min (30 US gpm)
1F		2859 ± 103 kPa (415 ± 15 psi)	P1 − 414± 34 kPa (P1 − 60 ± 5 psi)	386 ± 55 kPa (56 ± 8 psi)
2F
3F
4F
5F
6F
7F
8F
1R
2R
3R
4R
5R
6R
7R
8R

Table 11

High Idle Pressure Check	Input Speed (1850 ± 10 rpm)
Gear Range	Pump Pressure	Speed Clutch Pressure "P1"	Direction Clutch Pressure "P2"	Lubrication Pressure	Lubrication Flow
N
1F
2F
3F
4F
5F
6F
7F
8F
1R
2R
3R
4R
5R
6R
7R
8R

Low Idle Pressure Check

Table 12

Low Idle Pressure Check	Input Speed (700 ± 30 rpm)
Gear Range	Pump Pressure	Speed Clutch Pressure "P1"	Direction Clutch Pressure "P2"	Lubrication Pressure	Lubrication Flow
N	265 kPa (385 psi) Minimum	621 ± 41 kPa (90 ± 6 psi)	0	159 ± 69 kPa (23 ± 10 psi)	41.7 L/min (11 US gpm)
1F		251 kPa (365 psi) Minimum	P1 − 414± 34 kPa (P1 − 60 ± 5 psi)	41 ± 21 kPa (6 ± 3 psi)
2F
3F
4F
5F
6F
7F
8F
1R
2R
3R
4R
5R
6R
7R
8R

Table 13

Low Idle Pressure Check	Input Speed (700 ± 30 rpm)
Gear Range	Pump Pressure	Speed Clutch Pressure "P1"	Direction Clutch Pressure "P2"	Lubrication Pressure	Lubrication Flow
N
1F
2F
3F
4F
5F
6F
7F
8F
1R
2R
3R
4R
5R
6R
7R
8R

Contamination Control

Table 14

ISO Particle Count

Sample the test bench oil supply.

________/________Particle Count

Table 15

______________________________________ Technician

______________________________________ Supervisor