Bench Test Procedure for a 120K, 120K Series 2, 12K, 140K, 140K Series 2, and 160K Motor Grader Transmission {3030, 3065, 3073, 3167} Caterpillar

Motor Grader

120K (S/N: SZN1-UP; JAP1-UP)

120K Series 2 (S/N: SZS1-UP; SZZ1-UP)

12K (S/N: JJA1-UP; SZP1-UP)

140K (S/N: JPA1-UP; SZL1-UP)

140K Series 2 (S/N: SZW1-UP)

160K (S/N: SZM1-UP; JBP1-UP)

Introduction

© 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

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.

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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

Installation Procedure

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Illustration 3	g06069164

1. Install Tooling (A) to the test stand.
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   Illustration 4	g06069166

2. Use a hoist to install the transmission onto Tooling (A). The weight of the transmission is 907 kg (2000 lb).
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   Illustration 5	g06069172

3. Remove Cover (1).
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4. Remove Cover (2).
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5. Remove Cover (3) if applicable.
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6. Remove Plug (4).
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7. Install air fitting (5).
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   Illustration 10	g06069218

8. Remove Cover (6) and Plugs (7) and (8).
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   Illustration 11	g06069224

9. Remove Plug (9).
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   Illustration 12	g06069228

10. Remove Cover (10).
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    Illustration 13	g06069236

11. Remove Cover (11).
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    Illustration 14	g06069238

12. Remove Magnetic Screen (12).
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    Illustration 15	g06069253

13. Install Tooling (B).
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    Illustration 16	g06071138

14. Install Tooling (C).
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    Illustration 17	g06071152

15. Using the hoist and pry bar, align the transmission with the input drive shaft.

16. Connect the input drive shaft to Tooling (C).
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    Illustration 18	g06071155

17. Close and latch drive shaft guard.
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    Illustration 19	g03375318

18. Tighten all four castle nuts and jack bolts.
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    Illustration 20	g06071164

19. Install Tooling (D) to both sides of the transmission to prevent movement during testing.
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    Illustration 21	g06071176

20. Install Tooling (E).
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    Illustration 22	g06071617

21. Install Tooling (F).
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    Illustration 23	g06071760

22. Install Tooling (G).
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    Illustration 24	g06071765

23. Install Tooling (H).
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    Illustration 25	g06071774

24. Install Tooling (J) to Tooling (H).
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    Illustration 26	g06071814

25. Install Tooling (K).

    Note: Install 6V-3965 Fitting after all other fittings.

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    Illustration 27	g06071887

26. Install Tooling (L).
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    Illustration 28	g06072288

27. Install Tooling (M).
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    Illustration 29	g06071900
    Gravity Feed

28. Connect Hose Assembly (13) from the oil supply to Tooling (F).
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    Illustration 30	g06072295
    Pump Flow

29. Connect Hose Assembly (14) from Tooling (G) to Flowmeter 1 (in).
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    Illustration 31	g06072316
    Controls (in)

30. Connect Hose Assembly (15) from Flowmeter 1 (out) to Tooling (L).
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    Illustration 32	g06101723
    Controls (out)/Cooler Flow

31. Connect Hose Assembly (16) from Tooling (K) to Flowmeter 2 (in).
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    Illustration 33	g06101729
    Lube (in)

32. Connect Hose Assembly (17) from Flowmeter 2 (out) to Tooling (J).
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    Illustration 34	g06072347
    Scavenge Oil

33. Connect Hose Assembly (18) from Tooling (E) to sump or tank return port.
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    Illustration 35	g06072354
    Output Shaft 5 Lube Pressure

34. Connect pressure gauge (19) to Tooling (M).
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    Illustration 36	g06072370
    (20) Clutch 4 (21) Clutch 5 (22) Clutch 6 (23) Clutch 7 (24) Clutch 8

35. Connect pressure gauges to pressure taps (20 - 24).
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    Illustration 37	g06072380
    (25) Clutch 1 (26) Clutch 2 (27) Clutch 3

36. Connect pressure gauges to pressure taps (25-27).
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    Illustration 38	g06072386
    Main Relief Pressure

37. Connect a pressure gauge to pressure tap (28).
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    Illustration 39	g06072392
    Lube Pressure

38. Connect pressure gauge (29) to Tooling (H).
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    Illustration 40	g06072452
    Cooler Pressure

39. Connect pressure gauge (30) to Tooling (K)
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    Illustration 41	g06073570
    Pump Pressure

40. Connect pressure gauge (31) to Tooling (G).
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    Illustration 42	g06073582

41. Connect air supply hose (32) to the transmission. Maintain a minimum 552 kPa (80 psi) air supply.
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    Illustration 43	g06073597

42. Install Tooling (N) to the transmission.
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    Illustration 44	g06073602

43. Connect Tooling (N) to a suitable location.
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    Illustration 45	g06073591

44. Connect Tooling (N) to Tooling (P). Refer to Tool Operating Manual , NEHS0996 for the correct operating instructions.

Test Procedure

TA3 Navigation

1. Select "Motor Graders".

2. Select "140K-Ser2".

Harness Test

1. Make sure that Tooling (N) is properly connected.

2. Use Tooling (P) to perform the Harness Test.

3. Record the Values in Table 6.

Start Checks

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.
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   Illustration 46	g02720621

2. With the transmission in NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 800 ± 20 rpm.

3. Shift the transmission through all gear ranges to eliminate air from the transmission controls.

4. Check for excessive drag or lockup in all gears.

5. Verify correct clutch engagement with Table 4.
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   Table 4

   Clutch Engagement
   Gear	Cl 1	Cl 2	Cl 3	Cl 4	Cl 5	Cl 6	Cl 7	Cl 8
   N					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

Low Idle Checks

1. In NEUTRAL position, adjust the input rotation to 800 ±20 rpm.

2. Record Pump Flow, Lube Flow, Pump Pressure, Cooler Pressure, Main Relief Pressure, and Horse Power Loss in Table 8 or 9.

3. Confirm all values with Table 7.

4. Shift the transmission through all gears and repeat Steps2 through 3.

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

Low Idle Clutch Pressure Check

1. In NEUTRAL position, adjust the input rotation to 800 ±20 rpm.

2. Record Clutch Pressures in Table 11.

3. Confirm values with Table 10.

4. Shift the transmission through all gears and repeat Steps 2 through 3.

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

High Idle Checks

1. In NEUTRAL position, adjust the input rotation to 2000 ±20 rpm.

2. Record Pump Flow, Lube Flow, Output Shaft Lube Pressure, Lube Pressure, Pump Pressure, Cooler Pressure, Main Relief Pressure, and Horse Power Loss in Table 13 or 14.

3. Confirm all values with Table 12.

4. Adjust the input rotation to 800 ±20 rpm.

5. Shift the transmission through all gears and repeat Steps 2 through 4.

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

   Note: Only check Output Lube Pressure in NEUTRAL.

High Idle Clutch Pressure Check

1. In NEUTRAL position, adjust the input rotation to 2000 ±20 rpm.

2. Record Clutch Pressures in Table 16.

3. Confirm all values with Table 15.

4. Adjust the input rotation to 800 ±20 rpm.

5. Shift the transmission through all gears and repeat Steps 2 through 4.

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

Lube Bypass Check

1. Shift the transmission to NEUTRAL position.

2. Slowly adjust the input speed from 800 rpm to 2100 rpm.

3. Watch for Lube Relief Pressure to stop increasing as input rotation increases.

4. Lube bypass should occur at 517 ± 34 kPa (75 ± 5 psi)

5. Record the Lube bypass pressure in Table 17.

Cooler Bypass Check

1. Shift the transmission to NEUTRAL position.

2. Slowly adjust the input speed from 800 rpm to 2100 rpm.

3. Using Tooling (J) to slowly restrict Cooler Flow (Controls out) until Cooler Flow (Controls out) starts to drop.

4. Record Cooler bypass pressure in Table 18.

5. Open Tooling (J).

6. Stop input rotation.

Contamination Control

1. Take an oil sample of the test bench oil supply. Oil contamination sample must meet ISO 16/13 standards.

2. Record the results in Table 19.

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

Transmission Bench Test Data Sheet

Harness Test

Low Idle Checks

Low Idle Clutch Pressure Check

High Idle Checks

High Idle Clutch Pressure Check

Lube Bypass Check

Cooler Bypass Check

Contamination Control