Bench Test Procedure For a 14M and 16M Motor Grader Transmission {3030, 3073, 3167} Caterpillar

Bench Test Procedure For a 14M and 16M Motor Grader Transmission {3030, 3073, 3167}

Usage:

16M B9H

Motor Grader: 14M (S/N: B9J1-UP; R9J1-UP); 14M Series 3 (S/N: E9S1-UP; N9S1-UP); 16M (S/N: B9H1-UP; R9H1-UP); 16M Series 3 (S/N: E9Y1-UP; N9Y1-UP)

Introduction

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Table 1
Revision	Summary of Changes in REHS3446
09	Updated Installation Procedure.Updated Test Procedures and Tables.
08	Added new serial prefixes. Updated pressures and flows in High Idle and Low Idle checks.
07	Updated Introduction. Updated arrangement numbers in Table 2.
06	Removed references to Cooler Flows throughout document.
05	Updated effectivity and added arrangement numbers to Table 2.

© 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 questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. To address an urgent need, 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

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Table 2
Machine Model	Transmission Arrangement
14M	253-8407, 396-3305
14M3	381-0675
16M	253-8407, 396-3305
16M3	381-0675

Canceled Part Numbers and Replaced Part Numbers

This document may not 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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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.

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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 often 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.

Tools Needed

Note: Pressures will be sensitive to tooling setup. The diameter of the hose, the diameter of a fitting, and extra filtering can affect pressure. The required tools that are listed in Table 3 were used to develop this test procedure.

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Table 3
Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9584	Rail As	2
	439-5592⁽¹⁾	Rail As	2
	1U-9585	Block Gp (Transmission Mounting)	1
	FT-2277	Support	1
	421-5663	Lifting Eye Assembly	2
	8T-4193	Bolt (M16X2.00X50 mm)	1
B	136-3648	Adapter As	1
C	1U-9131	Drive Adapter (Key)⁽²⁾	1
C	1U-9359	Drive Adapter⁽³⁾	1
D	4C-4701	Spindle Adapter	1
	2J-5245	Bolt (3/8-16X1.25 inch)	4
	4B-4278	Washer	4
E	369-5916	Link Bracket	2
E	1U-9722	Load Binder As (Ratchet Type)	3
F⁽⁴⁾	172-6423	Dust Cap	1
	6V-5684	Bolt (M12X1.75X45 mm)	1
	9M-1974	Hard Washer	1
G	6V-3965	Fitting	2
G	3J-1907	O-Ring Seal	2
H	5P-8905	O-Ring Adapter	1
	2S-4078	O-Ring Seal	1
	5P-4674	O-Ring Adapter	1
	3E-6769	O-Ring Seal	1
	5P-7814	O-Ring Seal	1
	5P-4675	Adapter	1
	6V-3966	Fitting As	1
J	1U-8300	Fitting	1
	6V-3965	Fitting	1
	8C-9024	Fitting As	1
	144-8618	Adapter	1
	5P-0492	Adapter	1
K	5P-7701	O-Ring Seal	1
	5P-0492	Adapter	1
	8C-9024	Nipple (Plain)	1
L	3E-6746	O-Ring Seal	1
	1U-9869	Flange	1
	3B-7257	Reducer Bushing	1
	8C-9024	Nipple (Plain)	1
	8T-9515	Bolt (M10X1.50X40 mm)	4
M	8C-9025	Quick Coupler	1
	3B-7749	Pipe Nipple	1
	3B-6500	Elbow	1
	8C-9024	Fitting As	1
N	8C-9025	Quick Coupler	1
	120-6843	Ball Valve	1
	8C-9024	Fitting As	1
P	1U-9869	Flange	1
	3B-7257	Reducer Bushing	1
	8C-9024	Fitting As	1
	3E-6746	O-Ring Seal	1
	8T-9515	Bolt	4
Q	144-7791	Pipe Connector	1
	1U-9879	Adapter	1
	5P-1294	Hose (70 cm)	1
	5P-0597	Hose Clamp	2
	5L-6669	Reducer Bushing	1
R	1P-4579	Half Flange	2
	9U-7446	Adapter	1
	1U-8301	Fitting	1
	8C-9024	Fitting As	1
	6V-3965	Fitting	1
	6V-5684	Bolt	4
	5P-8245	Hard Washer	4
S	6V-7483	Adapter	1
	9B-3523	Bushing	1
	3D-8884	Elbow	1
	6V-3966	Fitting As	1
T	2P-8421	O-Ring Adapter	1
	6V-3965	Fitting	1
	6V-8076	Elbow	1
U⁽⁵⁾	9W-1454	Cover	1
	6V-3966	Nipple (Quick Disconnect)	1
	5P-5863	O-Ring Seal	1
V	2S-4078	O-Ring Seal	1
	5P-8905	O-Ring Adapter	1
	3E-6769	O-Ring Seal	1
	5P-4674	O-Ring Adapter	1
	5P-7814	O-Ring Seal	1
	5P-4675	O-Ring Adapter	1
	6V-3966	Nipple (Quick Disconnect)	1
W	3J-1907	O-Ring Seal	1
W	6V-3965	Nipple (Quick Disconnect)	1
X	277-2362	Transmission Analyzer Gp	1
Y	FT-3222⁽⁶⁾	Adapter Cable (Stub)	1
	306-0397	Adapter Cable As (Test)	1
	306-6388	Adapter Cable As (Test)	1
Z⁽⁷⁾	4C-9910	Portable Hydraulic Tester	1
AA⁽⁷⁾	8T-0855	Pressure Gauge ( 0 - 3447 kPa (0 - 500 psi))	12
AA⁽⁷⁾	6V-4144	Quick Connect Coupler	12
BB⁽⁷⁾	8T-0854	Pressure Gauge ( 0 - 965 kPa (0 - 140 psi))	8
BB⁽⁷⁾	6V-4144	Quick Connect Coupler	8

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⁽¹⁾	Use if test bed is flush with the floor
⁽²⁾	This drive adapter is used with the small drive shaft.
⁽³⁾	This drive adapter is used with the large drive shaft.
⁽⁴⁾	Refer to "Illustation 3".
⁽⁵⁾	Refer to "Illustration 4".
⁽⁶⁾	For Series 3 Motor Graders
⁽⁷⁾	Optional Tooling if needed with Test Bench.

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Illustration 3	g01338106

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Illustration 4	g01338099

FT Drawings

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Illustration 5	g03831077
FT-2277

Installation Procedure

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Illustration 6	g02711356

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Illustration 7	g01335715

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Illustration 8	g03735397

Install Tooling (A).
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Illustration 9 g01335717
Use a hoist to install the transmission on the test bench. The weight of the transmission is 1043 kg (2300 lb).
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Illustration 10 g03735423
Remove cover (1).
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Illustration 11 g03735427
Install Tooling (B).
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Illustration 12 g03735456
Install tooling (C) on Tooling (B).
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Illustration 13 g03735477
Install Tooling (D).
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Illustration 14 g03735524
Align the transmission with the input drive shaft.
Connect the drive shaft to Tooling (C).
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Illustration 15 g03735538
Close and latch the drive shaft guard.
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Illustration 16 g03375318
Tighten all four castle nuts and jack bolts.
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Illustration 17 g03735570
Install Tooling (E) to prevent movement during testing.
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Illustration 18 g03738605
Remove yoke assembly (2).
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Illustration 19 g03738609
Remove dust cap (3) from yoke assembly (2).
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Illustration 20 g03738617
Install Tooling (F) to yoke assembly (2).
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Illustration 21 g03735594
Install yoke assembly (2) to the transmission output shaft.
Note: A spacer may need to be used to keep the dust cap from contacting the housing/plate.
Note: The 172-6423 dust cap must be replaced with a dust cap that is not modified after testing is complete. Replace this cap before the machine is returned to service.
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Illustration 22 g06041397
Remove plugs/covers (3).
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Illustration 23 g06041582
Install Tooling (G) and (H).
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Illustration 24 g06041587
Install Tooling (J).
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Illustration 25 g06042045
Install Tooling (K).
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Illustration 26 g06042061
Install Tooling (L).
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Illustration 27 g06042073
Install Tooling (M) onto Tooling (K).
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Illustration 28 g06042086
Install Tooling (N) onto Tooling (M).
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Illustration 29 g06042600
Install Tooling (P).
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Illustration 30 g06042603
Install Tooling (Q).
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Illustration 31 g06042612
Install Tooling (R).
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Illustration 32 g06042618
Remove Plug (4).
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Illustration 33 g06042728
Install Tooling (S).
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Illustration 34 g06042743
Remove Plug (5).
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Illustration 35 g06042749
Install Tooling (T).
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Illustration 36 g06042759
Remove Cover (6).
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Illustration 37 g06047020
Install Tooling (U).
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Illustration 38 g06047048
Remove Plug (7).
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Illustration 39 g06047169
Install Tooling (V).
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Illustration 40 g06051097

Gravity Feed
Connect Hose Assembly (8) from Oil Supply to Tooling (Q).
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Illustration 41 g06051114

Scavenge Oil Return
Connect Hose Assembly (9) from Tooling (P) to drain.
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Illustration 42 g06051128

Pump Flow
Connect Hose Assembly (10) from Tooling (R) to Flowmeter 1 (in).
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Illustration 43 g06051132

Controls (in)
Connect Hose Assembly (11) from Flowmeter 1 (out) to Tooling (L).
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Illustration 44 g06055042

Controls (out)
Connect Hose Assembly (12) from Tooling (J) to Flowmeter 2 (in).
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Illustration 45 g06055051

Lube (in)/Cooler Flow
Connect Hose Assembly (13) from Flowmeter 2 (out) to Tooling (N).
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Illustration 46 g06056700
Install Tooling (W).
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Illustration 47 g06055058

0 - 4000 kPa (0 - 580 psi)
Parking Break Pressure
Connect pressure gauge (14) to Tooling (W).
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Illustration 48 g06055062

0 - 4000 kPa (0 - 580 psi)
Pump Pressure
Connect pressure gauge (15) to Tooling (R).
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Illustration 49 g06055066

0 - 965 kPa (0 - 140 psi)
Flywheel Lube Pressure
Connect pressure gauge (16) to Tooling (G).
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Illustration 50 g06055072

0 - 965 kPa (0 - 140 psi)
Lube Relief Pressure
Connect pressure gauge (17) to Tooling (H).
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Illustration 51 g06055078

0 - 965 kPa (0 - 140 psi)
Cooler Pressure
Connect pressure gauge (18) to Tooling (J).
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Illustration 52 g06055083

0 - 4000 kPa (0 - 580 psi)
Differential Lock Pressure
Connect pressure gauge (19) to Tooling (G).
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Illustration 53 g06055094

0 - 4000 kPa (0 - 580 psi)
Inlet Relief Pressure
Connect a pressure gauge to pressure tap (20).
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Illustration 54 g06055102

0 - 4000 kPa (0 - 580 psi)
(21) Clutch 1
(22) Clutch 2
Connect pressure gauges to pressure taps (21) and (22).
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Illustration 55 g06055113

0 - 4000 kPa (0 - 580 psi)
(23) Clutch 3
(24) Clutch 4
(25) Clutch 5
(26) Clutch 6
(27) Clutch 7
(28) Clutch 8
Connect pressure gauges to pressure taps (23), (24), (25), (26), (27), and (28).
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Illustration 56 g06055123

0 - 965 kPa (0 - 140 psi)
Input Shaft Lube Pressure
Connect pressure gauge (29) to Tooling (V).
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Illustration 57 g06055137

0 - 965 kPa (0 - 140 psi)
Shaft 2 Lube Pressure
Connect pressure gauge (30) to Tooling (U).
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Illustration 58 g06055131

0 - 965 kPa (0 - 140 psi)
Shaft 3 Lube Pressure
Connect a pressure gauge to pressure tap (31).
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Illustration 59 g06055146

0 - 965 kPa (0 - 140 psi)
Shaft 4 Lube Pressure
Connect pressure gauge (32) to Tooling (T).
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Illustration 60 g06055150

0 - 965 kPa (0 - 140 psi)
Output Shaft Lube Pressure
Connect pressure gauge (33) to Tooling (S).
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Illustration 61 g06055156
Install Tooling (X).
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Illustration 62 g06055158
Connect Tooling (X) to Tooling (Y). Refer to Tool Operating Manual, NEHS0966 for the correct operating instructions.

Test Procedure

TA3 Navigation

Select "Motor Graders".
Select "16M-24V".

Harness Test

Make sure that Tooling (X) is properly connected.
Use Tooling (Y) to perform the harness test.
Record the values in Table 6.
Note: Do not continue testing until harness test passes.

Preliminary Checks

Refer to Testing and Adjusting, RENR8482, "14M and 16M Motor Graders Power Train" for the correct adjusting procedures.

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 during the test.
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Illustration 63 g02720621
With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 800 rpm.
Note: The input shaft will be rotated in a counterclockwise direction during this test. The direction is determined as you face the drive motor of the test bench.
Note: An input speed of at least 800 rpm must be maintained during the test to prevent the engagement of the parking brake.
Shift the transmission through all directions and through all speed ranges to eliminate air from the transmission controls.
Check for lockup or excessive drag in all speed ranges.

Confirm the correct clutch engagement with Table 4.

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Table 4
Clutch Engagement Check
Gear	Clutch
Gear	1	2	3	4	5	6	7	8
N					X			X
P					X			X
F1	X					X	X
F2		X		X			X
F3		X			X		X
F4	X				X		X
F5	X					X		X
F6		X		X				X
F7	X			X				X
F8	X				X			X
R1			X			X	X
R2			X	X			X
R3			X		X		X
R4			X			X		X
R5			X	X				X
R6			X		X			X

Stop the input rotation.

Low Idle Checks

Adjust the input rotation to 800 rpm.
Shift the transmission to the PARK position.
Record Pump Flow, Lube Flow, Shaft 2 Pressure, Shaft 3 Pressure, Shaft 4 Pressure, Output Shaft Pressure, Inlet Relief Pressure, Parking Brake Pressure, Differential Lock Pressure, and Pump Pressure in Table 8.
Shift the transmission through ranges FORWARD 1, FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, FORWARD 7, FORWARD 8, NEUTRAL, REVERSE 1, REVERSE 2, REVERSE 3, REVERSE 4, REVERSE 5, and REVERSE 6. Repeat Step 3 for each gear range.
Note: Always shift back to NEUTRAL when shifting between FORWARD and REVERSE.
Shift the transmission to the NEUTRAL position.
Stop the input rotation.
Verify that all values match the specifications in Table 7.

Clutch Pressure Checks (Low Idle)

Adjust the input rotation to 800 rpm.
Shift the transmission to the PARK position.
Record the pressures of the activated clutches in Table 10.
Shift the transmission through ranges FORWARD 1, FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, FORWARD 7, FORWARD 8, NEUTRAL, REVERSE 1, REVERSE 2, REVERSE 3, REVERSE 4, REVERSE 5, and REVERSE 6. Repeat Step 3 for each gear range.
Note: Always shift back to NEUTRAL when shifting between FORWARD and REVERSE.
Shift the transmission to NEUTRAL position.
Stop the input rotation.
Verify that all values match the specifications in Table 9 or are within 70 kPa (10 psi) of Inlet Relief Pressure.

High Idle Checks

Adjust the input speed to 800 rpm.
Shift the transmission to the PARK position.
Adjust the input rotation to 2100 rpm.
Record Pump Flow, Lube Flow, Input Shaft Pressure, Shaft 2 Pressure, Shaft 3 Pressure, Shaft 4 Pressure, Output Shaft Pressure, Cooler Pressure, Inlet Relief Pressure, Parking Brake Pressure, Lube Relief Pressure, Differential Lock Pressure, Flywheel Lubrication Pressure, and Pump Pressure in Table 12.
Adjust the input speed to 800 rpm.
Shift the transmission through ranges FORWARD 1, FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, FORWARD 7, FORWARD 8, NEUTRAL, REVERSE 1, REVERSE 2, REVERSE 3, REVERSE 4, REVERSE 5, and REVERSE 6. Repeat Step 3 through Step 5 for each gear range.
Note: Always shift back to NEUTRAL when shifting between FORWARD and REVERSE.
Shift the transmission to the NEUTRAL position.
Stop the input rotation.
Verify that all values match the specifications in Table 11.

Clutch Pressure Checks (High Idle)

Adjust the input rotation to 800 rpm.
Shift the transmission to the PARK position.
Adjust the input rotation to 2100 rpm.
Record the pressures of the activated clutches in Table 14.
Adjust the input rotation to 800 rpm.
Shift the transmission through ranges FORWARD 1, FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, FORWARD 7, FORWARD 8, NEUTRAL, REVERSE 1, REVERSE 2, REVERSE 3, REVERSE 4, REVERSE 5, and REVERSE 6.
Note: Always shift back to NEUTRAL when shifting between FORWARD and REVERSE.
Repeat Steps 3 through 5.
Shift the transmission to NEUTRAL position.
Stop the input rotation.
Verify that all values match the specifications in Table 13 or are within 70 kPa (10 psi) of Inlet Relief Pressure.

Lube Bypass Check

Shift the transmission to the NEUTRAL position.
Slowly adjust the input speed from 800 rpm to 2100 rpm.
Watch for Lube Relief Pressure to stop increasing as input rotation increases.
Lube bypass should occur at approximately 1600 rpm with a pressure of 379 ± 34 kPa (55 ± 5 psi).
Record the Lube bypass pressure in Table 15.

Cooler Bypass Check

Shift the transmission to the NEUTRAL position.
Slowly adjust the input speed from 800 rpm to 2100 rpm.
Use Tooling (N) to slowly restrict Cooler Flow (Lube In) until Cooler Flow (Lube In) starts to drop.
Cooler bypass should occur at a delta pressure of 517 ± 34 kPa (75 ± 5 psi) (Cooler Pressure-Lube Pressure).
Note: Bypass may not occur at the cracking of the bypass valve. You may need to close Tooling (N) more to achieve full shifting of bypass valve.
Record Pump Flow, Lube Flow (Cooler Flow), Shaft 3 Lube Pressure, and Cooler Bypass Valve Pressure in Table 16.
Open Tooling (N).
Stop input rotation.

Contamination Control

Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.
Record the results in Table 17.
Remove the transmission from the test bench if the test bench oil supply is within specifications.

Transmission Bench Test Data Sheet

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Table 5
CATERPILLAR	Transmission Bench Test Data Sheet	Test Date:_______
		Model:_______
Work Order:_______		Serial No.:_______

Solenoid Test

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Table 6
Solenoid Test	Solenoid 1	Solenoid 2	Solenoid 3	Solenoid 4	Solenoid 5	Solenoid 6	Solenoid 7	Solenoid 8
Solenoid Test	ohms	ohms	ohms	ohms	ohms	ohms	ohms	ohms

Low Idle Checks

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Table 7
Low Idle Checks Input Speed (800 rpm)
Gear	P	N	1F	2F	3F	4F	5F	6F	7F	8F	1R	2R	3R	4R	5R	6R
Pump Flow	68 ± 7.5 L/min (18 ± 2 US gpm)
Lube Flow	49 ± 7.5 L/min (13 ± 2 US gpm)
Shaft 2 Press.	138 ± 14 kPa (20 ± 2 psi)		28 ± 14 kPa (4 ± 2 psi)
Shaft 3 Press.	131 ± 14 kPa (19 ± 2 psi)		28 ± 14 kPa (4 ± 2 psi)
Shaft 4 Press.	131 ± 14 kPa (19 ± 2 psi)		28 ± 14 kPa (4 ± 2 psi)
Output Shaft Press.	131 ± 14 kPa (19 ± 2 psi)		28 ± 14 kPa (4 ± 2 psi)
Inlet Relief Press.	2206 ± 69 kPa (320 ± 10 psi)
Parking Brake Press.	0.0 kPa (0.0 psi)	2206 ± 69 kPa (320 ± 10 psi)
Diff. Lock Press.	2206 ± 69 kPa (320 ± 10 psi)
Pump Press.	2344 ± 69 kPa (340 ± 10 psi)

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Table 8
Pressure Check (Low Idle) Input Speed (800 rpm)
Gear	P	N	1F	2F	3F	4F	5F	6F	7F	8F	1R	2R	3R	4R	5R	6R
Pump Flow	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Lube Flow	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Shaft 2 Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Shaft 3 Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Shaft 4 Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Output Shaft Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Inlet Relief Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Parking Brake Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Diff. Lock Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Pump Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___

Clutch Pressure Checks (Low Idle)

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Table 9
Gear	Clutch Pressures Low Idle (800 rpm)
	Direction			Speed			Range
	FWD HI	FWD LO	REV	2ND	3RD	1ST	LO	HI
	1	2	3	4	5	6	7	8
Park	X	X	X	X	2206 ± 69 kPa (320 ± 10 psi)	X	X	2206 ± 69 kPa (320 ± 10 psi)
N	X	X	X	X	2206 ± 69 kPa (320 ± 10 psi)	X	X	2206 ± 69 kPa (320 ± 10 psi)
1F	2206 ± 69 kPa (320 ± 10 psi)	X	X	X	X	2206 ± 69 kPa (320 ± 10 psi)	2206 ± 69 kPa (320 ± 10 psi)	X
2F	X	2206 ± 69 kPa (320 ± 10 psi)	X	2206 ± 69 kPa (320 ± 10 psi)	X	X	2206 ± 69 kPa (320 ± 10 psi)	X
3F	X	2206 ± 69 kPa (320 ± 10 psi)	X	X	2206 ± 69 kPa (320 ± 10 psi)	X	2206 ± 69 kPa (320 ± 10 psi)	X
4F	2206 ± 69 kPa (320 ± 10 psi)	X	X	X	2206 ± 69 kPa (320 ± 10 psi)	X	2206 ± 69 kPa (320 ± 10 psi)	X
5F	2206 ± 69 kPa (320 ± 10 psi)	X	X	X	X	2206 ± 69 kPa (320 ± 10 psi)	X	2206 ± 69 kPa (320 ± 10 psi)
6F	X	2206 ± 69 kPa (320 ± 10 psi)	X	2206 ± 69 kPa (320 ± 10 psi)	X	X	X	2206 ± 69 kPa (320 ± 10 psi)
7F	2206 ± 69 kPa (320 ± 10 psi)	X	X	2206 ± 69 kPa (320 ± 10 psi)	X	X	X	2206 ± 69 kPa (320 ± 10 psi)
8F	2206 ± 69 kPa (320 ± 10 psi)	X	X	X	2206 ± 69 kPa (320 ± 10 psi)	X	X	2206 ± 69 kPa (320 ± 10 psi)
1R	X	X	2206 ± 69 kPa (320 ± 10 psi)	X	X	2206 ± 69 kPa (320 ± 10 psi)	2206 ± 69 kPa (320 ± 10 psi)	X
2R	X	X	2206 ± 69 kPa (320 ± 10 psi)	2206 ± 69 kPa (320 ± 10 psi)	X	X	2206 ± 69 kPa (320 ± 10 psi)	X
3R	X	X	2206 ± 69 kPa (320 ± 10 psi)	X	2206 ± 69 kPa (320 ± 10 psi)	X	2206 ± 69 kPa (320 ± 10 psi)	X
4R	X	X	2206 ± 69 kPa (320 ± 10 psi)	X	X	2206 ± 69 kPa (320 ± 10 psi)	X	2206 ± 69 kPa (320 ± 10 psi)
5R	X	X	2206 ± 69 kPa (320 ± 10 psi)	2206 ± 69 kPa (320 ± 10 psi)	X	X	X	2206 ± 69 kPa (320 ± 10 psi)
6R	X	X	2206 ± 69 kPa (320 ± 10 psi)	X	2206 ± 69 kPa (320 ± 10 psi)	X	X	2206 ± 69 kPa (320 ± 10 psi)

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Table 10
Gear	Clutch Pressures
	Direction			Speed			Range
	FWD HI	FWD LO	REV	2ND	3RD	1ST	LO	HI
	1	2	3	4	5	6	7	8
Park	X	X	X	X	_____	X	X	_____
Neutral	X	X	X	X	_____	X	X	_____
1F	_____	X	X	X	X	_____	_____	X
2F	X	_____	X	_____	X	X	_____	X
3F	X	_____	X	X	_____	X	_____	X
4F	_____	X	X	X	_____	X	_____	X
5F	_____	X	X	X	X	_____	X	_____
6F	X	_____	X	_____	X	X	X	_____
7F	_____	X	X	_____	X	X	X	_____
8F	_____	X	X	X	_____	X	X	_____
1R	X	X	_____	X	X	_____	_____	X
2R	X	X	_____	_____	X	X	_____	X
3R	X	X	_____	X	_____	X	_____	X
4R	X	X	_____	X	X	_____	X	_____
5R	X	X	_____	_____	X	X	X	_____
6R	X	X	_____	X	_____	X	X	_____

High Idle Checks

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Table 11
High Idle Checks Input Speed (2100 rpm)
Gear	P	N	1F	2F	3F	4F	5F	6F	7F	8F	1R	2R	3R	4R	5R	6R
Pump Flow	182 ± 8 L/min (48 ± 2 US gpm)
Lube Flow	155 ± 7.6 L/min (41 ± 2 US gpm)
Input Shaft Press.	379 ± 69 kPa (55 ± 10 psi)		131 ± 69 kPa (19 ± 10 psi)								152 ± 69 kPa (22 ± 10 psi)
Shaft 2 Press.	379 ± 69 kPa (55 ± 10 psi)		131 ± 69 kPa (19 ± 10 psi)								152 ± 69 kPa (22 ± 10 psi)
Shaft 3 Press.	379 ± 69 kPa (55 ± 10 psi)		179 ± 69 kPa (26 ± 10 psi)								138 ± 69 kPa (20 ± 10 psi)
Shaft 4 Press.	379 ± 69 kPa (55 ± 10 psi)		179 ± 69 kPa (26 ± 10 psi)								172 ± 69 kPa (25 ± 10 psi)
Output Shaft Press.	379 ± 69 kPa (55 ± 10 psi)		186 ± 69 kPa (27 ± 10 psi)								179 ± 69 kPa (26 ± 10 psi)
Inlet Relief Press.	2517 ± 69 kPa (365 ± 10 psi)
Parking Brake Press.	0.0 kPa (0.0 psi)	2517 ± 69 kPa (365 ± 10 psi)
Lube Relief Press.	379 ± 69 kPa (55 ± 10 psi)		159 ± 69 kPa (23 ± 10 psi)
Diff. Lock Press.	2517 ± 69 kPa (365 ± 10 psi)
Flywheel Lube Press.	758 ± 69 kPa (110 ± 10 psi)	827 ± 69 kPa (120 ± 10 psi)	552 ± 69 kPa (80 ± 10 psi)
Pump Press.	2482 ± 138 kPa (360 ± 20 psi)		2896 ± 138 kPa (420 ± 20 psi)

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Table 12
Pressure Check (High Idle)		Input Speed (2100 rpm)
Gear	P	N	1F	2F	3F	4F	5F	6F	7F	8F	1R	2R	3R	4R	5R	6R
Pump Flow	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Lube Flow	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Input Shaft Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Shaft 2 Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Shaft 3 Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Shaft 4 Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Output Shaft Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Inlet Relief Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Parking Brake Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Lube Relief Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Diff. Lock Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Flywheel Lube Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___
Pump Press.	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___	___

Clutch Pressure Check (High Idle)

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Table 13
Gear	Clutch Pressures High Idle (2100 rpm)
	Direction			Speed			Range
	FWD HI	FWD LO	REV	2ND	3RD	1ST	LO	HI
	1	2	3	4	5	6	7	8
Park	X	X	X	X	2517 ± 69 kPa (365 ± 10 psi)	X	X	2517 ± 69 kPa (365 ± 10 psi)
N	X	X	X	X	2517 ± 69 kPa (365 ± 10 psi)	X	X	2517 ± 69 kPa (365 ± 10 psi)
1F	2517 ± 69 kPa (365 ± 10 psi)	X	X	X	X	2517 ± 69 kPa (365 ± 10 psi)	2517 ± 69 kPa (365 ± 10 psi)	X
2F	X	2517 ± 69 kPa (365 ± 10 psi)	X	2517 ± 69 kPa (365 ± 10 psi)	X	X	2517 ± 69 kPa (365 ± 10 psi)	X
3F	X	2517 ± 69 kPa (365 ± 10 psi)	X	X	2517 ± 69 kPa (365 ± 10 psi)	X	2517 ± 69 kPa (365 ± 10 psi)	X
4F	2517 ± 69 kPa (365 ± 10 psi)	X	X	X	2517 ± 69 kPa (365 ± 10 psi)	X	2517 ± 69 kPa (365 ± 10 psi)	X
5F	2517 ± 69 kPa (365 ± 10 psi)	X	X	X	X	2517 ± 69 kPa (365 ± 10 psi)	X	2517 ± 69 kPa (365 ± 10 psi)
6F	X	2517 ± 69 kPa (365 ± 10 psi)	X	2517 ± 69 kPa (365 ± 10 psi)	X	X	X	2517 ± 69 kPa (365 ± 10 psi)
7F	2517 ± 69 kPa (365 ± 10 psi)	X	X	2517 ± 69 kPa (365 ± 10 psi)	X	X	X	2517 ± 69 kPa (365 ± 10 psi)
8F	2517 ± 69 kPa (365 ± 10 psi)	X	X	X	2517 ± 69 kPa (365 ± 10 psi)	X	X	2517 ± 69 kPa (365 ± 10 psi)
1R	X	X	2517 ± 69 kPa (365 ± 10 psi)	X	X	2517 ± 69 kPa (365 ± 10 psi)	2517 ± 69 kPa (365 ± 10 psi)	X
2R	X	X	2517 ± 69 kPa (365 ± 10 psi)	2517 ± 69 kPa (365 ± 10 psi)	X	X	2517 ± 69 kPa (365 ± 10 psi)	X
3R	X	X	2517 ± 69 kPa (365 ± 10 psi)	X	2517 ± 69 kPa (365 ± 10 psi)	X	2517 ± 69 kPa (365 ± 10 psi)	X
4R	X	X	2517 ± 69 kPa (365 ± 10 psi)	X	X	2517 ± 69 kPa (365 ± 10 psi)	X	2517 ± 69 kPa (365 ± 10 psi)
5R	X	X	2517 ± 69 kPa (365 ± 10 psi)	2517 ± 69 kPa (365 ± 10 psi)	X	X	X	2517 ± 69 kPa (365 ± 10 psi)
6R	X	X	2517 ± 69 kPa (365 ± 10 psi)	X	2517 ± 69 kPa (365 ± 10 psi)	X	X	2517 ± 69 kPa (365 ± 10 psi)

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Table 14
Gear	Clutch Pressures
	Direction			Speed			Range
	FWD HI	FWD LO	REV	2ND	3RD	1ST	LO	HI
	1	2	3	4	5	6	7	8
Park	X	X	X	X	_____	X	X	_____
Neutral	X	X	X	X	_____	X	X	_____
1F	_____	X	X	X	X	_____	_____	X
2F	X	_____	X	_____	X	X	_____	X
3F	X	_____	X	X	_____	X	_____	X
4F	_____	X	X	X	_____	X	_____	X
5F	_____	X	X	X	X	_____	X	_____
6F	X	_____	X	_____	X	X	X	_____
7F	_____	X	X	_____	X	X	X	_____
8F	_____	X	X	X	_____	X	X	_____
1R	X	X	_____	X	X	_____	_____	X
2R	X	X	_____	_____	X	X	_____	X
3R	X	X	_____	X	_____	X	_____	X
4R	X	X	_____	X	X	_____	X	_____
5R	X	X	_____	_____	X	X	X	_____
6R	X	X	_____	X	_____	X	X	_____

Lube Bypass Check

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Table 15
Lube Bypass Check NEUTRAL position
Input Rotation	Lube Bypass Pressure
2100 rpm	379 ± 34 kPa (55 ± 5 psi)
	___________kPa (psi)

Cooler Bypass Check

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Table 16
Cooler Bypass Check	Input Speed (2100 rpm)
Gear	NEUTRAL
Cooler Relief Pressure	517 ± 34 kPa (75 ± 5 psi)
Cooler Relief Pressure	___________kPa (psi)

Contamination Control

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Table 17
Contamination Control	Sample the test bench oil supply. *ISO 4406 is 16/13 or better	________/________Particle Count

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Table 18
______________________________________ Technician	______________________________________ Supervisor

Caterpillar Information System:

C9 Engine for the 816F Series 2 Landfill Compactor, the 815F Series 2 Soil Compactor, and the 814F Series 2 Wheel Dozer Component Location

773G and 775G OFF-Highway Trucks Machine Systems Tire and Rim (Front) - Remove and Install

259B3 Compact Track Loader, 247B3 and 257B3 Multi Terrain Loaders and 216B3, 226B3, 236B3, 242B3 and 252B3 Skid Steer Loaders Engine Supplement Gear Motor (Fan) - Install

259B3 Compact Track Loader, 247B3 and 257B3 Multi Terrain Loaders and 216B3, 226B3, 236B3, 242B3 and 252B3 Skid Steer Loaders Engine Supplement Gear Motor (Fan) - Remove

816F Series 2 Landfill Compactor, 815F Series 2 Soil Compactor and 814F Series 2 Wheel Dozer Machine Systems Pilot Valve - Install

816F Series 2 Landfill Compactor, 815F Series 2 Soil Compactor and 814F Series 2 Wheel Dozer Machine Systems Pilot Valve - Disassemble

816F Series 2 Landfill Compactor, 815F Series 2 Soil Compactor and 814F Series 2 Wheel Dozer Machine Systems Pilot Valve - Assemble

816F Series 2 Landfill Compactor, 815F Series 2 Soil Compactor and 814F Series 2 Wheel Dozer Machine Systems Pilot Valve - Remove

770 and 772 Off-Highway Trucks Power Train Position Switch (Truck Body)

2006/12/11 A Different Parking Brake Valve Is Now Used {4282}

246C, 256C, 262C, 262C2 and 272C Skid Steer Loaders Machine Systems Refrigerant Condenser and Mounting - Remove and Install

2007/01/15 A New Protection Cover for the Ground Level Control on the Bumper Is Now Available {1408}

160M Motor Grader Tire Shipping Pressure

2007/11/05 Troubleshooting the "Water Separator Has Water" Warning Message {1263, 1439}

2007/01/01 A New Solenoid is Now Used for the Throttle Control on Paving Compactors {1265, 1276}

773F Off-Highway Truck and 775F Off-Highway Truck Engine Supplement Fuel Transfer Pump - Remove and Install

2007/04/02 Recommendations for Differences in Tire Sizes {4203}

Salvage of the Bores in the Front Frame for the Hitch Pins {7113} Salvage of the Bores in the Front Frame for the Hitch Pins {7113}

2007/01/22 Shims Are Now Available for the Wear Pads on Certain Telehandlers {6501}

3508B Engine for D11R Track-Type Tractors E009 High Altitude Derate

236B, 246B, 246C, 252B, 256C, 262B, 262C, 262C2 and 272C Skid Steer Loaders Engine Supplement Radiator and Hydraulic Oil Cooler - Remove

236B, 246B, 246C, 252B, 256C, 262B, 262C, 262C2 and 272C Skid Steer Loaders Engine Supplement Radiator and Hydraulic Oil Cooler - Install

3508B Engine for D11R Track-Type Tractors E2089 Oil Renewal System Cannot Operate

16M Motor Grader Machine Systems Ripper Lift Cylinder - Remove and Install




Illustration 47	g06055058
0 - 4000 kPa (0 - 580 psi) Parking Break Pressure




Illustration 48	g06055062
0 - 4000 kPa (0 - 580 psi) Pump Pressure




Illustration 49	g06055066
0 - 965 kPa (0 - 140 psi) Flywheel Lube Pressure




Illustration 50	g06055072
0 - 965 kPa (0 - 140 psi) Lube Relief Pressure




Illustration 51	g06055078
0 - 965 kPa (0 - 140 psi) Cooler Pressure




Illustration 52	g06055083
0 - 4000 kPa (0 - 580 psi) Differential Lock Pressure




Illustration 53	g06055094
0 - 4000 kPa (0 - 580 psi) Inlet Relief Pressure




Illustration 54	g06055102
0 - 4000 kPa (0 - 580 psi) (21) Clutch 1 (22) Clutch 2




Illustration 55	g06055113
0 - 4000 kPa (0 - 580 psi) (23) Clutch 3 (24) Clutch 4 (25) Clutch 5 (26) Clutch 6 (27) Clutch 7 (28) Clutch 8




Illustration 56	g06055123
0 - 965 kPa (0 - 140 psi) Input Shaft Lube Pressure




Illustration 9	g01335717




Illustration 10	g03735423




Illustration 11	g03735427




Illustration 12	g03735456




Illustration 57	g06055137
0 - 965 kPa (0 - 140 psi) Shaft 2 Lube Pressure




Illustration 58	g06055131
0 - 965 kPa (0 - 140 psi) Shaft 3 Lube Pressure




Illustration 59	g06055146
0 - 965 kPa (0 - 140 psi) Shaft 4 Lube Pressure




Illustration 60	g06055150
0 - 965 kPa (0 - 140 psi) Output Shaft Lube Pressure