Bench Test Procedure For a 834B Wheel Dozer And a 836 Landfill Compactor Transmission{1376, 3030, 3073} Caterpillar

Landfill Compactor:

836 (S/N: 3RL1-UP)

Wheel Dozer:

834B (S/N: 92Z1-UP)

Introduction

© 2012 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.

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 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 need, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

• Cat Dealer Techinical Communicator

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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 in order 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.

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.

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.

Installation Procedure

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Illustration 1	g01323961

1. Install Tooling (A) .

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Illustration 2	g01323973
Typical Example

2. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1350.79 kg (2978 lb).

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Illustration 3	g01323981

3. Install Tooling (B) .

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

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Illustration 4	g01324000

5. 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.

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Illustration 5	g01324003
Typical Example

6. Align the transmission with the input drive shaft.

7. Connect the input drive shaft to Tooling (B) .

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Illustration 6	g01324004

8. Install the drive shaft guard.

9. Install Tooling (C) to the transmission in order to prevent movement during testing.

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Illustration 7	g01324022

10. Install Tooling (D) .

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Illustration 8	g01324024

11. Install Tooling (E) .

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Illustration 9	g01324139

12. Install Tooling (F) .

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Illustration 10	g01324159

13. Remove cover (2) .

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Illustration 11	g01324163

14. Remove plug (3), plug (4), and plug (5) from the top of the control valve.

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Illustration 12	g01324174

15. Install Tooling (G), Tooling (H), and Tooling (J) .

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Illustration 13	g01324181

16. Install Tooling (K) .

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Illustration 14	g01324213

17. Install Tooling (L) .

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Illustration 15	g01324239

18. Install Tooling (M) .

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Illustration 16	g01324202

19. Connect Hose Assembly (6) from the outlet of the pressurized flow meter on the test bench to Tooling (D) .

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Illustration 17	g01324205

20. Connect Hose Assembly (7) from Tooling (E) to the inlet of the "Number 2" flow meter on the test bench.

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Illustration 18	g01324207

21. Connect Hose Assembly (8) from the outlet of the "Number 2" flow meter on the test bench to Tooling (F). The "Number 2" flow meter will measure lube flow.

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Illustration 19	g01324225
(9) Lubrication Pressure

22. Connect pressure gauge (9) to Tooling (L) .

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Illustration 20	g01324232
(10) "P1" Speed Clutch Pressure and Initial Pressure (11) "P2" Direction Clutch Pressure (12) "P3" Torque Converter Inlet Pressure

23. Connect pressure gauge (10) to Tooling (G) .

24. Connect pressure gauge (11) to Tooling (H) .

25. Connect pressure gauge (12) to Tooling (J) .

Test Procedure

Preliminary Checks

Note: Refer to Testing and Adjusting, SENR2606, "834B Wheel Tractor & 836 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 68.137 ± 1.893 L/min (18.0 ± .5 US gpm).

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Illustration 21	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.

   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.

4. Shift the transmission through all speed ranges in order to eliminate air from the transmission controls.

5. Stop the input rotation.

Initial Pressure Check

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Illustration 22	g01324287

1. Remove load piston plug (13) from the transmission controls.

2. Shift the transmission to the NEUTRAL position.

3. Adjust the input flow to 68.137 ± 1.893 L/min (18.0 ± .5 US gpm).

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

5. Record initial "P1" pressure in Table 6.

6. Initial "P1" pressure must be 530.90 ± 34.47 kPa (77 ± 5 psi).

7. Stop the input rotation.

8. Stop the input flow.

9. Replace load piston plug (13) .

Pressure Differential Valve Check

1. Adjust the input flow to 151.416 ± 1.893 L/min (40.0 ± .5 US gpm).

2. Shift the transmission to any gear range except NEUTRAL.

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

4. "P2" pressure must remain at 0.00 kPa (0 psi).

5. Shift the transmission to the NEUTRAL position.

6. Record "P1" pressure and "P2" pressure in Table 7.

7. "P1" pressure must be 2654.4826 ± 103.4214 kPa (385 ± 15 psi) and "P2" pressure must be P1 - 379.21 ± 55.16 kPa (55 ± 8 psi).

8. Stop the input rotation.

9. Stop the input flow.

Torque Converter Ratio Valve Check

1. Adjust the input flow to 68.137 ± 1.893 L/min (18.0 ± .5 US gpm).

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

3. Shift the transmission to any gear range except NEUTRAL.

4. Adjust Tooling (F) in order to temporarily block lube flow to the transmission.

5. Record "P3" pressure in Table 8.

6. "P3" pressure must be 951.48 ± 55.16 kPa (138 ± 8 psi).

7. Adjust Tooling (F) in order to allow lube flow into the transmission.

8. Stop the input rotation.

9. Stop the input flow.

Lubrication Pressure Check

1. Adjust the input flow to 94.635 ± 1.893 L/min (25.0 ± .5 US gpm).

2. Shift the transmission to FORWARD 3.

3. Adjust the input rotation to 1000 ± 30 rpm.

4. Record the lubrication pressure in Table 9.

5. Lubrication pressure must be 89.63 ± 6.89 kPa (13 ± 1 psi).

6. Shift the transmission to the NEUTRAL position.

7. Stop the input rotation.

8. Stop the input flow.

Lube Circuit Check

1. Adjust the input flow to 151.416 ± 1.893 L/min (40.0 ± .5 US gpm).

2. Shift the transmission to the FORWARD 1 position.

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

4. Record "P1" pressure, "P2" pressure, "P3" pressure, and lubrication pressure in Table 10.

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

6. Shift the transmission through positions FORWARD 2, FORWARD 3, FORWARD 4, NEUTRAL, REVERSE 1, REVERSE 2, REVERSE 3, and REVERSE 4. Repeat Step 1 through Step 5 for each gear range.

7. Verify that all test points match the values in Table 4.
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   Table 4

   Lube Circuit Check Specifications
   "P1"	2654.48 ± 103.42 kPa (385 ± 15 psi)
   "P2"	379.21 ± 55.16 kPa (55 ± 8 psi)
   "P3"	951.4769 ± 55.1581 kPa (138 ± 8 psi)
   Lubrication Pressure	89.63 ± 6.89 kPa (13 ± 1 psi)
   Lube Flow	Input Flow - 34.07 L/min (9 US gpm) minimum

Contamination Control

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

2. Record the results in Table 11.

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

Transmission Bench Test Data Sheet

Initial Pressure Check

Pressure Differential Valve Check

Torque Converter Ratio Valve Check

Lubrication Pressure Check

Lube Circuit Check

Contamination Control