- Load Haul Dump
- R2900G (S/N: GLK1-UP; JLK1-UP; NLK1-UP)
- R3000H (S/N: RCM1-UP; RCY1-UP)
Introduction
Revision | Summary of Changes in REHS3625 |
03 | Added prefix NLK and arrangement 488-8199.
Added prefix RCY and removed arrangement 382-9012. Standardized. |
02 | Updated Title. |
01 | Updated Effectivity and added arrangement numbers |
© 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 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
Machine Model | Transmission Arrangement |
R2900G | |
R3000H |
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 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.
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. |
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. |
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.
Required Tools | |||
---|---|---|---|
Tool | Part Number | Part Description | Qty |
A | Rail As | 2 | |
Bracket As | 2 | ||
Crossmember | 1 | ||
Bolt (20-2.00X80 mm) | 4 | ||
Hard Washer | 4 | ||
Bolt (5/8-11X4.75 inch) | 4 | ||
Hard Washer | 8 | ||
Full Nut | 4 | ||
B | Adapter | 1 | |
Bolt (1/2-20X1.25 inch) | 4 | ||
Lockwasher | 4 | ||
C | Drive Adapter As | 1 | |
Bolt (3/8-16X1.25 inch) | 4 | ||
Lockwasher | 4 | ||
D | Drive Adapter (KEY)(1) | 1 | |
E | Drive Adapter(2) | 1 | |
F | Load Binder As (Ratchet Type) | 4 | |
Link Bracket As | 4 | ||
Bolt (3/4-10X2.5 inch) | 4 | ||
Hard Washer | 4 | ||
G | Fitting As (Plain) | 1 | |
Fitting | 1 | ||
Adapter | 1 | ||
Half Flange | 2 | ||
Fitting As (Quick Disconnect) | 1 | ||
O-Ring Seal | 1 | ||
Bolt (7/16-14X1.125 inch) | 4 | ||
Hard Washer | 4 | ||
H | Fitting As (Plain) | 1 | |
Fitting | 1 | ||
Adapter | 1 | ||
Half Flange | 2 | ||
Fitting As (Quick Disconnect) | 1 | ||
O-Ring Seal | 1 | ||
Bolt (7/16-14X1.125 inch) | 4 | ||
Hard Washer | 4 | ||
J | Fitting As (Plain) | 1 | |
Fitting | 1 | ||
Adapter | 1 | ||
Half Flange | 2 | ||
Fitting As (Quick Disconnect) | 1 | ||
O-Ring Seal | 1 | ||
Bolt (7/16-14X1.125 inch) | 4 | ||
Hard Washer | 4 | ||
K | Fitting As (Quick Disconnect) | 1 | |
O-Ring Seal | 1 | ||
L | Ball Valve | ||
M | Transmission Analyzer Tool Gp | 1 | |
Adapter Cable As (Transmission Analyzer) | 1 | ||
Adapter Cable As | 1 | ||
N | Pressure Gauge (0 to 4,000 kPa (0 to 580 psi)) | 2 | |
Coupler | 2 | ||
P | Pressure Gauge (0 to 1,000 kPa (0 to 140 psi)) | 1 | |
Coupler | 1 | ||
R | Pressure Gauge (0 to 250 kPa (0 to 36 psi)) | 1 | |
Coupler | 1 |
(1) | This drive adapter is used with the small drive shaft. |
(2) | This drive adapter is used with the large drive shaft. |
Installation Procedure
- Install Tooling (A), to the test stand.
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Illustration 4 g02751216 - Use a hoist to install the transmission on the test bench. The weight of the transmission is
1451 kg (3200 lb) .Show/hide tableIllustration 5 g02751697 - Install Tooling (B) to the input yoke.
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Illustration 6 g02751756 - Install Tooling (C) to Tooling (B).
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Illustration 7 g02751857 - Install Tooling (D) to Tooling (C).
Note: Tooling (D) will adapt to the small drive shaft. If you are using the large drive shaft, install Tooling (E) on Tooling (D).
Show/hide tableIllustration 8 g02751879 - Align the transmission with the input drive shaft.
- Connect the input drive shaft to Tooling (D).
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Illustration 9 g02751919 - Install the drive shaft guard.
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Illustration 10 g03375318 - Tighten all four castle nuts and jack bolts.
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Illustration 11 g02753280 - Install Tooling (F) to the input and output ends of the transmission.
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Illustration 12 g02755939 - Remove cover plate (1).
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Illustration 13 g02753559 - Remove filter assembly (2).
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Illustration 14 g02753436 - Remove drain plug (3).
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Illustration 15 g02756216 - Install Tooling (G).
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Illustration 16 g02756259 - Install Tooling (H).
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Illustration 17 g02755241 - Remove Plug (4) and Cover Plate (5).
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Illustration 18 g02755337 - Install Tooling (J).
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Illustration 19 g02755376 - Install Tooling (K).
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Illustration 20 g02755477 (6) Converter Inlet Oil - Connect hose assembly (6) from Tooling (H) to the No. 2 flow meter inlet.
Note: The No. 2 flow meter will measure the converter inlet oil that is returning to the test bench.
Show/hide tableIllustration 21 g02755517 (7) Supply Oil - Connect hose assembly (7) from the pressurized flow meter to Tooling (G).
Note: The flow meter will measure the flow of the supply oil.
Show/hide tableIllustration 22 g02756056 (8) Lube Oil
(L) Ball Valve - Connect hose assembly (8) from the No. 2 flow meter outlet to Tooling (L).
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Illustration 23 g02756381 (9) Transmission Control Supply Pressure Note: If you are using individual pressure gauges to measure the pressures, refer to Table 3 for the correct pressure gauges.
- Connect a pressure gauge to pressure tap (9).
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Illustration 24 g02753381 (10) Transmission Lubrication - Connect a pressure gauge to pressure tap (10) to Tooling (K).
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Illustration 25 g02756437 - Connect Tooling (M) to the transmission.
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Illustration 26 g02753176 - Connect Tooling (M) to a suitable location.
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Illustration 27 g02629190 Tooling (M) - Connect Tooling (M) to a power source. Refer to Tool Operating Manual, NEHS0966 for the correct operating instructions.
Illustration 3 | g02751541 |
TA3 Navigation
- Select “Load Haul Dump”.
- Select “R2900-24V”.
Harness Test
- Make sure that the harness is properly connected.
- Use Tooling (M) to perform the harness test.
- Record the values in Table 6.
Note: Do not continue testing until Harness Test passes.
Start Checks
- 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 to34 °C (95 °F) . Maintain this temperature for the duration of the test. - Adjust the input flow to
74 ± 4 L/min (19 ± 1 US gpm) .Show/hide tableIllustration 28 g02720621 - With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 725 ± 35 rpm.
- Shift the transmission through all gears to eliminate air from the transmission controls.
- The reference for the lube pressure is
21 ± 7 kPa (3 ± 1 psi) .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.
- Record the value in Table 8.
- 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 - Stop the input rotation.
- Stop the input flow.
Note: Refer to Testing and Adjusting, RENR7807, "R2900G Load Haul Dump Power Train" for the correct adjusting procedures.
Initial Pressure Check
- Remove cover (11).
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Illustration 30 g02753057 (12) Direction Clutch Pressure "P2"
(13) Speed Clutch Pressure "P1" - Connect pressure gauges to pressure taps (12) and (13).
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Illustration 31 g02755581 Load piston plug removed. - Remove load piston plug (14).
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Illustration 32 g02758517 (15) P3 Pressure Tap for the converter inlet oil pressure. - Connect pressure gauge to pressure tap (15).
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Illustration 33 g02752937 - Cover the transmission. Use a suitable clean cover.
- Adjust the input flow to
74 ± 4 L/min (19 ± 1 US gpm) . - With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 725 ± 35 rpm.
- The "P1" pressure must be
531 ± 35 kPa (77 ± 5 psi) . - Record the value in Table 9.
- Stop the input rotation.
- Stop the input flow.
- Install load piston (14).
Illustration 29 | g02752957 |
Torque Converter Inlet Ratio Valve
- Adjust the input flow to
74 ± 4 L/min (19 ± 1 US gpm) . Maintain this flow during this check. - With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 725 ± 35 rpm.
- Shift the transmission to FORWARD 1.
- Use Tooling (L) to momentarily block the lube flow.
- The converter inlet pressure must be
951 ± 55 kPa (138 ± 8 psi) . - Open the lube flow.
- Record the value in Table 10.
Lube Circuit Check
- Adjust the input flow until the lube flow is
152 ± 4 L/min (40 ± 1 US gpm) . Maintain this flow during this check. - Adjust the input rotation to 725 ± 35 rpm.
- Shift the transmission to FORWARD 3.
- Adjust the input rotation to 1500 ± 30 rpm.
- The lube pressure must be within
± 14 kPa (± 2 psi) of the average for this arrangement. Reference is117 ± 14 kPa (17 ± 2 psi) . Refer to "Collecting the Test Data" in this document. - Record the value in Table 11.
Clutch Leakage Check
- Adjust the input flow to
152 ± 4 L/min (40 ± 1 US gpm) . Maintain this flow during this check. - Adjust the input rotation to 700 ± 35 rpm.
- Shift the transmission to the FORWARD 1 position.
- Adjust the input rotation to 2000 ± 80 rpm.
- Record the input flow in Table 12.
- Record the lube flow in Table 12.
- The leakage is obtained by subtracting the lube flow from the input flow.
- Record the calculation in Table 12.
- Adjust the input rotation to 700 ± 35 rpm.
- 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.
- The difference in lube flow between the FIRST, THIRD, and FOURTH gear ranges and between FORWARD and REVERSE shall be no more than
2.3 L/min (0.6 US gpm) . - The difference in lube flow between SECOND and FIRST, THIRD, and FOURTH gear ranges must not exceed
3 L/min (0.8 US gpm) of the average for this arrangement. Reference is4.5 ± 3 L/min (1.2 ± 0.8 US gpm) . Refer to "Collecting the Test Data" in this document. - Record the calculations in Table 12.
- Adjust the input rotation to 700 ± 35 rpm.
Contamination Control
- Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 18/15.
- Record the results in Table 13.
- Remove the transmission from the test bench if the test bench oil supply is within specifications.
Transmission Bench Test Data Sheet
CATERPILLAR | Transmission Bench Test Data Sheet | Test Date:_______ |
Model:_______ | ||
Work Order:_______ | Serial No.:_______ |
Harness Test
Harness Test | Solenoid 1 | Solenoid 2 | Solenoid 3 | Solenoid 4 | Solenoid 5 |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
Specifications
Specifications | ||
---|---|---|
Description | High Idle | Low Idle |
Input Speed | 2000 ± 30 rpm | 725 ± 35 rpm |
Input Flow | |
|
Minimum Lube Flow | - | |
Pressures | ||
"P1" Initial(1) | - | |
P1 | |
|
P2 | P1 − 379 ± 55 kPa
(P1 − 55 ± 8 psi) |
P1 − 379 ± 55 kPa
(P1 − 55 ± 8 psi) |
P3(2) | - | |
(1) | The load piston plug is removed and the transmission is in the NEUTRAL position. |
(2) | The flow for the converter outlet is restricted. |
Start Checks
Lube Pressure | Input Speed (725 ± 35 rpm)
Input Flow |
_______kPa _______(psi) |
Primary Pressure Check
Initial Pressure | Input Speed (725 ± 35 rpm)
Input Flow |
_______kPa _______(psi) |
Torque Converter Inlet Ratio Valve
Torque Converter Inlet Ratio Valve | Input Speed (725 ± 35 rpm)
Input Flow |
_______kPa _______(psi) |
Lube Circuit Check
Lube Circuit Check | Gear Range FORWARD 3
Input Speed (1500 ± 30 rpm) Lube Flow |
||
Average Lube Pressure Of Arrangement | _______kPa _______(psi) |
Lube Pressure | _______kPa _______(psi) |
Clutch Leakage Check
Clutch Leakage Check | Input Speed (2000 ± 30 rpm)
Input Flow |
||||||||
Gear Range | N | F1 | F2 | F3 | F4 | R1 | R2 | R3 | R4 |
Input Flow |
______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ |
Lube Flow |
______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ |
Leakage |
______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ | ______ |
Contamination Control
ISO Particle Count | Sample the test bench oil supply. *ISO 4406 |
________/________Particle Count |
______________________________________ Technician |
______________________________________ Supervisor |