Bench Test Procedure For A 824C Wheel Dozer, 825C Soil Compactor, and 826C Landfill Compactor Transmission {3030, 3073} Caterpillar

Landfill Compactor

826C (S/N: 87X1-UP)

Soil Compactor

825C (S/N: 86X1-UP)

Wheel Dozer

824C (S/N: 85X1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS2836
02	Standardized.
01	Added new Introduction and Canceled Part Numbers section

© 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- specific transmission arrangements. 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. This 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:

• Cat Dealer Techinical Communicator

• Dealer Solution Network

• Cat Technical Representative

• Knowledge Network

Table 2

Machine Model	Transmission Arrangement
824C	3P-6809
825C	3P-6809
826C	3P-6809

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 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.

Show/hide table

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.

Show/hide table

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Show/hide table

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
	FT-1333	Support Adapters	1
B	FT-1081	Ring	1
C	FT-1423	Drive Adapter	1
D	FT-1420	Cover	1
E	1U-9722	Load Binder As (Ratchet Type)	2
F	1U-8304	Fitting	1
	9U-7445	Adapter	1
	1P-4578	Half Flange	2
	8C-9024	Nipple (Plain)	1
	6V-3965	Nipple (Quick Disconnect)	1
	8T-8917	Bolt (7/16-14X1.25 inch)	4
	5P-8244	Washer	4
G	120-6843	Ball Valve	1
	7F-6654	Nipple (Pipe)	2
	6B-9081	Reducing Bushing	2
	7X-7646	Nipple (Quick Disconnect)	1
	8C-9025	Coupler (Quick Disconnect)	1
H	1U-8304	Fitting	1
	9U-7446	Adapter	1
	1P-4579	Half Flange	2
	8C-9024	Nipple (Plain)	1
	6V-3965	Nipple (Quick Disconnect)	1
	8T-6973	Bolt (7/16-14X1.125 inch)	4
	5P-8244	Washer	4
U	1U-8301	Fitting	1
	9U-7445	Adapter	1
	1P-4578	Half Flange	2
	8C-9024	Nipple (Plain)	1
	6V-3965	Nipple (Quick Disconnect)	1
	8T-6973	Bolt (7/16-14X1.125 inch)	2
	8T-8916	Bolt (7/16-14X1.50 inch)	2
	5P-8244	Washer	4
J	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
K	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
L	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
M	5P-6586	Test Cover	1
N	7S-8887	Nipple (Quick Disconnect)	1
	5P-3501	Adapter	1
	3J-1907	O-Ring Seal	1
P	7S-8887	Nipple (Quick Disconnect)	1
	5P-3501	Adapter	1
	3J-1907	O-Ring Seal	1
Q	FT-1551	Shift Lever	1
R	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	3
	6V-4144	Coupler	3
S	8T-0854	Pressure Gauge (0 to 1,000 kPa (0 to 145 psi))	2
	6V-4144	Coupler	2
T	8T-0862	Pressure Gauge (-100 to 500 kPa (-15 to 72 psi))	1
	6V-4144	Coupler	1

FT Drawings

Illustration 3	g06053242
FT-1333

Illustration 4	g06055002
FT-1333

Illustration 5	g06055004
FT-1333

Illustration 6	g06055008
FT-1333

Illustration 7	g06023628
FT-1081

Illustration 8	g06054371
FT-1423 (Part 1)

Illustration 9	g06054373
FT-1423 (Part 2)

Illustration 10	g06034822
FT-1551 (Part 1)

Illustration 11	g06034829
FT-1551 (Part 2) (1) Item 1 Bracket As. Qty: 1 (2) Item 2 Block Qty: 2 (3) Item 3 Pin Qty: 4 (4) Item 4 Rod Qty: 2 (5) Item 5 Lever Qty: 2 (6) Item 6 Boss Qty: 2 (7) Item 7 Lever As. Items 4, 5, and 6 Qty: 2 (8) 2G-0111 Knob Qty: 2 (9) 9S-7381 Bolt Qty: 2 (10) Item 10 Link Qty: 2

Illustration 12	g06055016
FT-1420 (Part 1)

Illustration 13	g06055024
FT-1420 (Part 2)

Illustration 14	g06055035
FT-1420 (Part 3)

Illustration 15	g06055028
FT-1420 (Assembly)

Installation Procedure

Show/hide table

Illustration 16	g06054504

1. Install Tooling (A) to support the transmission.
   Show/hide table

   Illustration 17	g00888450
   Typical Example

2. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1542 kg (3400 lb).
   Show/hide table

   Illustration 18	g01209151

3. Install Tooling (B).

4. Install Tooling (C).

5. Install Tooling (D).
   Show/hide table

   Illustration 19	g01209245

6. Remove the drain plug from the bottom of the transmission.

7. Remove the cover, the magnetic tube, and the screen (1).

   Note: This will allow the oil to drain from the transmission during the test procedure.

   Show/hide table

   Illustration 20	g01209247
   Typical Example

8. Align the transmission with the input drive shaft.

9. Connect the input drive shaft to Tooling (C).
   Show/hide table

   Illustration 21	g01209271

10. Install the drive shaft guard.
    Show/hide table

    Illustration 22	g03802221

11. Tighten all four castle nuts and jack bolts.
    Show/hide table

    Illustration 23	g01209273

12. Fasten the transmission to the test bench by using Tooling (E).
    Show/hide table

    Illustration 24	g01209284

13. Install Tooling (F).
    Show/hide table

    Illustration 25	g01209334

14. Install Tooling (G) to Tooling (F).
    Show/hide table

    Illustration 26	g01209344

15. Install Tooling (H).
    Show/hide table

    Illustration 27	g06054511

16. Install Tooling (U).
    Show/hide table

    Illustration 28	g01209361
    (2) Rear Lubrication Inlet

17. Connect Hose Assembly (2) from the No. 1 flow meter outlet to Tooling (G).
    Show/hide table

    Illustration 29	g01209366
    (3) Torque Converter Outlet

18. Connect Hose Assembly (3) from Tooling (H) to the No. 1 flow meter inlet.
    Show/hide table

    Illustration 30	g01209369
    (4) Torque Converter and Transmission Inlet

19. Connect Hose Assembly (4) from the test bench to Tooling (U).
    Show/hide table

    Illustration 31	g01209379

20. Remove the yoke from the transfer gear output shaft (5).
    Show/hide table

    Illustration 32	g01209382

21. Remove the cover from the top of the transmission.

22. Remove the pipe plugs from the "P1", "P2", and "P3" pressure taps in the top of the control valve.

23. Install Tooling (J).
    Show/hide table

    Illustration 33	g01209387

24. Install Tooling (K).
    Show/hide table

    Illustration 34	g01209389

25. Install Tooling (L).
    Show/hide table

    Illustration 35	g01209391

26. Install Tooling (M).
    Show/hide table

    Illustration 36	g01209395

27. Remove the plug and install Tooling (N).
    Show/hide table

    Illustration 37	g01209396

28. Remove the plug and install Tooling (P).
    Show/hide table

    Illustration 38	g01209403
    (6) Speed Clutch Pressure "P1"

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

29. Connect a pressure line (6) to Tooling (J).
    Show/hide table

    Illustration 39	g01209407
    (7) Directional Clutch Pressure "P2"

30. Connect a pressure line (7) to Tooling (K).
    Show/hide table

    Illustration 40	g01209409
    (8) Torque Converter Inlet Pressure "P3"

31. Connect a pressure line (8) to Tooling (L).
    Show/hide table

    Illustration 41	g01209421
    (9) Lubrication Pressure

32. Connect a pressure line (9) to Tooling (N).
    Show/hide table

    Illustration 42	g01209433
    (10) Torque Converter Outlet Pressure

33. Connect a pressure line (10) to Tooling (H).
    Show/hide table

    Illustration 43	g01209439

34. Install Tooling (Q).

Test Procedure

Start Checks

Note: Refer to Testing and Adjusting, SENR7834-00, "824C Wheel Dozer, 825C Soil Compactor, and 826C Landfill Compactor Power Shift Transmission" 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 68 ± 4 L/min (18 ± 1 US gpm).
   Show/hide table

   Illustration 44	g02720621

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 760 ± 30 rpm.

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

5. Confirm the correct clutch engagement with Table 4.
   Show/hide table

   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

6. Stop the input rotation.

7. Stop the input flow.

Initial Pressure

Show/hide table

Illustration 45	g01209469

1. Remove the load piston plug (11) from the top of the controls.

2. Shift the transmission to NEUTRAL.

3. Adjust the input rotation to 760 ± 30 rpm.

4. Adjust input flow to 68 ± 4 L/min (18 ± 1 US gpm).

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

6. Record the value in Table 7.

7. Stop the input rotation.

8. Install the load piston plug (11).

Pressure Differential Valve

1. Place the directional selector in a position that is not NEUTRAL.

2. Adjust the input rotation to 2100 ± 30 rpm.

3. Adjust input flow to 178 ± 4 L/min (47 ± 1 US gpm). The "P2" directional clutch pressure must remain at zero.

4. Shift the directional selector to NEUTRAL. The "P2" pressure must be 379 ± 55 kPa (55 ± 8 psi).

5. Stop the input rotation and the supply flow.

6. Record the values in Table 8.

Torque Converter Inlet Relief Valve

1. Adjust the input rotation to 760 ± 30 rpm.

2. Adjust input flow to 68 ± 4 L/min (18 ± 1 US gpm).

3. Shift the transmission to any range except NEUTRAL.

4. Use Tooling (G) to momentarily block the flow at the torque converter outlet.

5. The "P3" torque converter inlet pressure must be 930 ± 69 kPa (135 ± 10 psi).

6. Open the lube flow.

7. Record the value in Table 9.

Lube Circuit Check

1. Shift the transmission to FORWARD 3.

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

3. The lubrication pressure must be within ± 14 kPa (± 2 psi) of the average lubrication pressure of the last 99 transmissions. Reference is 79 ± 14 kPa (11 ± 2 psi).

4. Record the value in Table 10.

Clutch Leakage

1. Adjust the input rotation to 2100 ± 30 rpm.

2. Adjust the input flow to 178 ± 4 L/min (47 ± 1 US gpm).

3. Shift the transmission to FORWARD 1.

4. Record the input flow in Table 11.

5. Record the lube flow in Table 11.

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

6. Record the leakage in Table 11.

7. 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 6 for each gear range.

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

8. The leakage difference between FIRST, THIRD, and FOURTH gears or between FORWARD and REVERSE should not exceed 2.3 L/min (0.6 US gpm).

9. The leakage difference between SECOND gear and FIRST, THIRD, and FOURTH gears must not exceed 3 L/min (0.8 US gpm) of the average difference of the last 99 transmissions. Reference is 5.3 ± 3 L/min (1.4 ± 0.8 US gpm).

10. Record the values in Table 11.

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 12.

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.:_______

Specifications

Table 6

Specifications
Description	High Idle	Low Idle
Input Speed	2100 ± 30 rpm	760 ± 30 rpm
Input Flow	178 ± 4 L/min (47 ± 1 US gpm)	68 ± 4 L/min (18 ± 1 US gpm)
Minimum Lube Flow	136 L/min (36 US gpm)	34 L/min (9 US gpm)
Pressures
"P1" Initial (1)	-	531 ± 34 kPa (77 ± 5 psi)
"P1"	2584 ± 138 kPa (375 ± 20 psi)	2206 kPa (320 psi) Minimum
"P2"	P1- 379 ± 55 kPa (P1- 55 ± 8 psi)	P1- 379 ± 55 kPa (P1- 55 ± 8 psi)
"P3" (2)	-	930 ± 69 kPa (135 ± 10 psi)
Torque Converter Outlet	468 ± 69 kPa (68 ± 10 psi)	393 ± 55 kPa (57 ± 8 psi)

(1)	The load piston plug (11) is removed and the transmission is in NEUTRAL.
(2)	Flow is restricted at the torque converter outlet.

Initial Pressure

Table 7

"P1" Clutch Pressure

Input Speed (760 ± 30 rpm) Input Flow 68 ± 4 L/min (18 ± 1 US gpm) Gear Range NEUTRAL Removed Load Piston Plug (11)

_______kPa _______(psi)

Pressure Differential Valve

Table 8

"P2" Directional Clutch Pressure	Input Speed (2100 ± 30 rpm) Input Flow 178 ± 4 L/min (47 ± 1 US gpm)
Any Gear Range (Excluding NEUTRAL)	_______kPa _______(psi)
Gear Range NEUTRAL	_______kPa _______(psi)

Torque Converter Inlet Relief Valve

Table 9

"P3" Torque Converter Inlet Pressure

Input Speed (760 ± 30 rpm) Input Flow 68 ± 4 L/min (18 ± 1 US gpm) Any Gear Range (Excluding NEUTRAL) Restricted Torque Converter Outlet

_______kPa _______(psi)

Lube Circuit Check

Table 10

Lube Pressure

Gear Range FORWARD 3 Lube Flow 95 ± 4 L/min (25 ± 1 US gpm)

_______kPa _______(psi)

Clutch Leakage Check

Table 11

Clutch Leakage Check		Input Speed (2100 ± 30 rpm) Input Flow 178 ± 4 L/min (47 ± 1 US gpm)
Gear Range	N	F1	F2	F3	F4	R1	R2	R3	R4
Input Flow	______	______	______	______	______	______	______	______	______
Lube Flow	______	______	______	______	______	______	______	______	______
Leakage	______	______	______	______	______	______	______	______	______
Averages		1F+3F+4F/3=_____________				1R+3R+4R/3=_____________

Contamination Control

Table 12

ISO Particle Count

Sample the test bench oil supply. *ISO 4406 is 16/13 or better

________/________Particle Count

Table 13

______________________________________ Technician

______________________________________ Supervisor