Bench Test Procedure for a 730, 730 Ejector, 730C, 730C Series 2, 730C Series 2 Ejector and 735. Articulated Truck Transmission {3030, 3073} Caterpillar

Articulated Truck

730 (S/N: 3F31-UP; 3T31-UP)

730 EJECTOR (S/N: 3F41-UP; 3T41-UP)

730C (S/N: LFF1-UP; TFF1-UP)

730C EJECTOR (S/N: LFH1-UP; TFH1-UP)

730C2 (S/N: 2T41-UP; 2L71-UP)

730C2 EJ (S/N: 2T51-UP; 2L81-UP)

735 (S/N: 3F51-UP; 3T51-UP)

Introduction

© 2018 Caterpillar All Rights Reserved. This document is for the use of Caterpillar 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 document 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 document 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 document must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

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 document 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. These tools are suggested and may very depending on availability and bench configuration.

Installation Procedure

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Illustration 3	g03454001

1. Install Tooling (A) to Test Bench.
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   Illustration 4	g03454010
   6V-7675 Bolt (M16x2x140 mm)

2. Install Tooling (A) on transmission.
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   Illustration 5	g03454014

3. Use a hoist to lift the transmission onto the Test Bench. The weight of the transmission along with Tooling (A) is 454 kg (1000 lb).
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   Illustration 6	g03454016
   8T-0207 Bolt (M16x2x100 mm) 8T-0358 Bolt (M16x2x90 mm)

4. Install Tooling (A) to the output sides of the transmission.
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   Illustration 7	g03454020
   6V-5844 Bolt (M16x2x35 mm)

5. Install Tooling (A) to the input sides of the transmission.
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   Illustration 8	g03454596

6. Install Tooling (B) to the transmission.
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   Illustration 9	g03454618

7. Install Tooling (C).
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   Illustration 10	g03454637

8. Use a hoist to install Tooling (D) onto Tooling (C).
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   Illustration 11	g03374665

9. Adjust and tighten collet on Tooling (D).

   Note: Refer to Special Instruction, SEHS8763, "Assembly and Operation of 1U-5999 Spindle Group Used for Testing Transmissions on Hydraulic Test Bench".

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   Illustration 12	g03454667

10. Install Tooling (E) onto Tooling (D).
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    Illustration 13	g03454676

11. Install Tooling (F) onto Tooling (E).
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    Illustration 14	g03454726

12. Use pry bars and a hoist to move the transmission forward and align the transmission with the input drive shaft.

13. Attach the input drive shaft to Tooling (F).
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    Illustration 15	g03374951

14. Close and latch the drive shaft guard.
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    Illustration 16	g03454758

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    Illustration 17	g03454767

15. Install Tooling (G) to both ends of the transmission.

    Note: On the output end of the transmission, route chain through the link brackets to prevent slippage. Refer to Illustration 16.

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    Illustration 18	g03457162

16. Tighten all four jack bolts and castle nuts on the test bench bed.
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    Illustration 19	g03454876
    Pump Flow (out)

17. Install Tooling (H) to the transmission.
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    Illustration 20	g03454885
    Controls (in)

18. Install Tooling (J) to the transmission.
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    Illustration 21	g03454895
    Torque Converter (out) on Left and Lube (in) on Right

19. Install Tooling (J) to the transmission.
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    Illustration 22	g03454918
    Torque Converter (out)

20. Install Tooling (K) onto Tooling (J).
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    Illustration 23	g03454958
    Pump Flow (out)

21. Connect Hose Assembly (1) from Tooling (H) to Flowmeter 1 (in).
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    Illustration 24	g03454978
    Controls (in)

22. Connect Hose Assembly (2) from Flowmeter 1 (out) to Tooling (J).
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    Illustration 25	g03455000
    Torque Converter (out)

23. Connect Hose Assembly (3) from Tooling (K) to Cooler (in).

24. Connect a Hose Assembly from Cooler (out) to Flowmeter 2 (in).
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    Illustration 26	g03455036
    Lube (in)

25. Connect Hose Assembly (4) from Flowmeter 2 (out) to Tooling (J).
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    Illustration 27	g03455180
    Spinde Drive Adapter Lube

26. Connect Hose Assembly (5) to Tooling (D).
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    Illustration 28	g03455456
    (6) Torque Converter (in) 965 kPa (140 psi) (7) Main Relief 3447 kPa (500 psi) (8) Lube (in) 965 kPa (140 psi)

27. Connect Pressure gauges to Pressure taps (6-8).
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    Illustration 29	g03455469
    Torque Converter (out) 965 kPa (140 psi)

28. Connect a Pressure gauge to Pressure tap (9).
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    Illustration 30	g03455477
    3447 kPa (500 psi) (10) Lockup Clutch (11) Clutch No. 1 (12) Clutch No. 2 (13) Clutch No. 3 (14) Clutch No. 4 (15) Clutch No. 5

29. Connect Pressure gauges to Pressure taps (10-15).
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    Illustration 31	g03455507

30. Connect Tooling (L) to the wiring harness on the transmission.
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    Illustration 32	g03455556

31. Connect Tooling (L) to Tooling (M).

32. Connect Tooling (M) to a power source. Refer to Tool Operating Manual, NEHS0966 for the correct operating instructions.

Test Procedure

TA3 Navigation

1. Select “OEM Transmissions”.

2. Select “CX31 OEM Truck-12V”.

Harness Test

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

2. Use Tooling (M) to perform the solenoid test.

3. Record the values in Table 6.

   Note: Do not continue testing until Harness Test passes.

Transmission Fill

Note: System capacity is 49 L (13 US gal).

1. Remove Dip Stick Assembly.

2. Fill the transmission with 19 L (5 US gal) of fluid.

3. With the transmission in NEUTRAL position, adjust the input rotation to approximately 300 rpm. Verify that control and lube flows are present. Verify that lube pressure is present.

4. With flows and pressure present, spin transmission for 1 minute to fill all hoses and valves.

5. Stop rotation and add 19 L (5 US gal) of fluid.

6. With the transmission in NEUTRAL position, adjust rotation back to 300 rpm. Verify that control and lube flows are present. Verify that lube pressure is present.

7. Reinstall Dip Stick Assembly and check oil level. Remove assembly and add oil with the transmission running. Monitor the level until full.

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 33	g02720621

2. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 600 rpm.

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

4. Verify that the active clutches are correct for each gear range. Refer to Table 4.
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   Table 4

   Clutch Engagement Check
   Gear	Cl 1	Cl 2	Cl 3	Cl 4	Cl 5	Lockup
   N					X
   R			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

5. Stop the input rotation.

Low Idle Pressure Checks

1. With the transmission in NEUTRAL position, adjust the input rotation to 600 ± 20 rpm.

2. Record the TC in, TC out, main relief, and lube pressures and horse power in Table 8.

3. Verify values with Table 7.

4. Record the clutch pressures in Table 10.

5. Verify the values with Table 9.

6. Shift the transmission to REVERSE.

7. Record the TC in, TC out, main relief, and lube pressures and horse power in Table 8.

8. Verify values with Table 7.

9. Record the clutch pressures in Table 10.

10. Verify the values with Table 9.

11. Shift the transmission back to NEUTRAL and then to FORWARD 1.

12. Record the TC in, TC out, main relief, and lube pressures and horse power in Table 8.

13. Verify values with Table 7.

14. Record the clutch pressures in Table 10.

15. Verify the values with Table 9.

16. Shift the transmission through gears FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, and FORWARD 6. Repeat Steps 12 through 15.

High Idle Pressure Checks

1. With the transmission in the NEUTRAL position, adjust the input rotation to 600 ± 20 rpm.

2. Adjust the input rotation up to 2100 ± 20 rpm.

3. Record TC in, TC out, main relief, and lube pressures and horse power in Table 12.

4. Verify values with Table 11.

5. Record the clutch pressures in Table 14.

6. Verify values with Table 13.

7. Adjust the input rotation back to 600 ± 20 rpm.

8. Shift the transmission to REVERSE.

9. Adjust the input rotation to 2100 ± 20 rpm.

10. Record TC in, TC out, main relief, and lube pressures and horse power in Table 12.

11. Verify values with Table 11.

12. Record the clutch pressures in Table 14.

13. Verify values with Table 13.

14. Adjust the input rotation to 600 ± 30 rpm and shift the transmission back to NEUTRAL.

15. Shift the transmission to FORWARD 1.

16. Adjust the input rotation to 2100 ± 20 rpm.

17. Record TC in, TC out, main relief, and lube pressures and horse power in Table 12.

18. Verify values with Table 11.

19. Record the clutch pressures in Table 14.

20. Verify values with Table 13.

21. Adjust the input rotation to 600 ± 20 rpm.

22. Shift the transmission through gears FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, and FORWARD 6. Repeat Steps 16 through 21.

Speed Sensor Test

1. With the transmission in NEUTRAL position, adjust the input rotation to 600 ± 20 rpm.

2. Shift the transmission to FORWARD 2.

3. Record Output Speed 1 and Output Speed 2 in Table 15.

4. Disconnect Speed Sensor 1 and connect Torque Converter Output Speed Sensor.

5. Record Torque Converter Output Speed in Table 15.

6. With the transmission in FORWARD 2, adjust the input speed to 2100 rpm.

7. Record Torque Converter Output Speed in Table 15.

8. Disconnect Torque Converter Output Speed Sensor and connect Speed Sensor 1.

9. Record Output Speed 1 and Output Speed 2 in Table 15.

10. Verify the values with data given in Table 15.

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 16.

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 Pressure Checks

High Idle Pressure Checks

Speed Sensor Test

Contamination Control