Bench Test Procedure for an 824K, 825K, and 826K Compactor Transmission {3030, 3030, 3167} Caterpillar

Landfill Compactor

826K (S/N: 2321-UP; 2L31-UP; 2T61-UP; SET1-UP)

Soil Compactor

825K (S/N: 2331-UP; 2L91-UP; 2T91-UP; SEE1-UP)

Wheel Dozer

824K (S/N: 2T21-UP; 2L41-UP; 2341-UP; RWB1-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

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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 additional 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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1. Install Tooling (A) to the test stand.
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2. Use a hoist to install the transmission on to Tooling (A). The weight of the transmission is 1814 kg (4000 lb).
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   Illustration 5	g03664265

3. Install Tooling (B) to the input end of the transmission.
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4. Use a hoist to install Tooling (C) to the input end of the transmission.
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5. Use a hoist to install Tooling (D) to Tooling (C).
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   Illustration 8	g03374665

6. 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" for additional information.

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   Illustration 9	g03479682

7. Install Tooling (E) onto Tooling (D).
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   Illustration 10	g03479696

8. Install Tooling (F) onto Tooling (E).
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9. Align the transmission with the input drive shaft.

10. Connect the input drive shaft with Tooling (F).
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    Illustration 12	g03581501

11. Close and latch the drive shaft guard.
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    Illustration 13	g03375318

12. Tighten all four castle nuts and jack bolts on the test bed.
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13. Install Tooling (H) to both ends of the transmission.

    Note: Route chains through Tooling (A) to prevent slippage during testing.

    Note: There is Tooling (H) on both sides on the input end of the transmission.

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14. Remove magnetic filter housing (1).
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15. Remove plug (2) from the bottom of the transmission.
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16. Remove plug (3).
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17. Remove cover (4).
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    Illustration 19	g03664314

18. Remove cover (5).
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    Illustration 20	g03664315
    Controls (in)

19. Install Tooling (J) underneath the transmission.
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    Illustration 21	g03664340
    Torque Converter (in)

20. Install Tooling (K) to the transmission.
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    Illustration 22	g03664341
    Torque Converter (out)

21. Install Tooling (L) to the transmission.
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    Illustration 23	g03664343
    Torque Converter (out)

22. Install Tooling (M) onto Tooling (L).
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    Illustration 24	g03664357
    Lube (in)

23. Install Tooling (N) to the transmission.
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    Illustration 25	g03664360

24. Connect Hose Assembly (6) from Pump Supply to Tooling (P).
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25. Connect Hose Assembly (7) from Tooling (P) to Flowmeter 1 (in).
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    Illustration 27	g03664370
    Controls (in)

26. Connect Hose Assembly (8) from Flowmeter 1 (out) to Tooling (J).
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    Illustration 28	g03664371

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27. Connect Hose Assembly (9) from Tooling (P) to Tooling (Q) (in).
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    Illustration 30	g03664378

28. Connect Hose Assembly (10) from Tooling (Q) to Flowmeter 3 (in).
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    Illustration 31	g03664382
    Torque Converter (in)

29. Connect Hose Assembly (11) from Flowmeter 3 (out) to Tooling (K).
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    Torque Converter (out)

30. Connect Hose Assembly (12) from Tooling (M) to Flowmeter 4 (in).
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    Lube (in)

31. Connect Hose Assembly (13) from Flowmeter 4 (out) to Tooling (N).
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    Illustration 34	g03664407
    Spindle Lube

32. Connect Hose Assembly (14) to Tooling (D)
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    Illustration 35	g03664409
    3447 kPa (500 psi) (15) Clutch No. 6 (16) Clutch No. 5 (17) Clutch No. 4 (18) Clutch No. 3 (19) Clutch No. 2 (20) Clutch No. 1

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    Illustration 36	g03667428

33. Connect Pressure Gauges to Pressure taps (15-20).

    Note: 394-1138 Transmission Ar for the 826K does not have a Clutch No. 4. Refer to Illustration 36.

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    Illustration 37	g03667435
    3447 kPa (500 psi) (21) Lockup Clutch

34. Connect a Pressure Gauge to Pressure tap (21).
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    Illustration 38	g03667440
    (22) Torque Converter (in) 965 kPa (140 psi) (23) Main Relief Pressure 3447 kPa (500 psi)

35. Connect a Pressure Gauge to Pressure taps (22) and (23).
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    Illustration 39	g03667528
    965 kPa (140 psi) (24) Torque Converter (out)

36. Connect a Pressure Gauge to Pressure tap (24).
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    Illustration 40	g03664421
    965 kPa (140 psi) (25) Lube (in)

37. Connect a Pressure Gauge to Pressure tap (25).
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    Illustration 41	g03664426

38. Install Tooling (R) to the transmission.
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    Illustration 42	g03667562

39. Connect Tooling (R) to Tooling (S). Refer to Tool Operating Manual, NEHS0996 for the correct operating instructions.

    Note: Make sure that the transmission is secured to the test bench. Tighten all bolts to the proper torque.

Test Procedure

TA3 Navigation

1. Select “Wheel Tractors”.

2. Select “824K-24V”, “825K-24V”, or “826K-24V”.

Harness Test

1. Make sure Tooling (R) is properly connected.

2. Use Tooling (S) to perform the harness test.

3. Record the values in Table 6.

   Note: Do not continue testing until Harness Test passes.

Start Check

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. Set the input flow to 106 ± 8 L/min (28 ± 2 US gpm).
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3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 20 rpm.

4. Adjust Tooling (Q) until a split flow of 45 ± 4 L/min (12 ± 1 US gpm) for controls and 61 ± 8 L/min (16 ± 2 US gpm)for TC (in) is achieved.

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

6. The lube pressure should be minimum 30 kPa (4 psi).

   Note: If there is no lube pressure after 30 seconds, stop the test and verify test stand and transmission connections.

7. 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

8. With the transmission in NEUTRAL position, measure Lube flow, and TC (in), Main Relief, TC (out), and Lube pressures.

9. Record the values in Table 8.

10. Confirm the values with Table 7.

    Note: If the values do meet acceptance criteria, stop the test and verify test stand, instrumentation hook-ups, calibration, and/or repair/adjust the transmission.

11. Set the input flow to 189 ± 8 L/min (50 ± 2 US gpm).

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

13. Adjust Tooling (Q) until a split flow of 91 ± 4 L/min (24 ± 1 US gpm) for controls and 98 ± 8 L/min (26 ± 2 US gpm) for TC (in) is achieved.

14. Wait until flows and pressures stabilize.

15. Repeat Steps 8 through 10.

Torque Converter Block Check

1. Set the input flow to 106 ± 8 L/min (28 ± 2 US gpm).

2. Adjust the input speed to 700 ± 20 rpm.

3. Adjust Tooling (Q) until a split flow of 45 ± 4 L/min (12 ± 1 US gpm) for controls and 61 ± 8 L/min (16 ± 2 US gpm) for TC (in) is achieved.

4. Shift the transmission to FORWARD 1.

5. Use Tooling (M) to block flow temporarily at the converter outlet.

6. The converter inlet and outlet pressures must be between 827 kPa (120 psi) and 1034 kPa (150 psi).

   Note: To prevent running the transmission dry, the maximum block time is 10 seconds.

7. Open the lube flow.

8. Record the value in Table 9.

Lube Circuit Check

1. Shift the transmission into FORWARD 2 and set the input speed to 1800 ± 20 rpm.

2. Adjust the input flow to achieve a Lube flow of 114 ± 8 L/min (30 ± 2 US gpm).

   Note: Input flow would be approximately 163 L/min (43 US gpm) with a split flow of 76 L/min (20 US gpm) for controls and 87 L/min (23 US gpm) for TC in.

3. Lube pressure must be 103 ± 21 kPa (15 ± 3 psi).

4. Record the value in Table 10.

Low Idle Pressure Checks

1. Set the input flow to 106 ± 8 L/min (28 ± 2 US gpm).

2. Adjust the input speed to 700 ± 20 rpm.

3. Adjust Tooling (Q) until a split flow of 45 ± 4 L/min (12 ± 1 US gpm) for controls and 61 ± 8 L/min (16 ± 2 US gpm) for TC (in) is achieved.

4. Shift the transmission to FORWARD 1.

5. Record Lube Flow, Lube, Main Relief, TC (in), TC (out) pressures, and Horse Power Loss in Table 13.

6. Confirm values with Table 11 or 12.

7. Record all Clutch pressures in Table 16.

8. Confirm values with Table 14 or 15.

9. Shift transmission through FORWARD 2, FORWARD 3, FORWARD 4, REVERSE 1, REVERSE 2, REVERSE 3, and REVERSE 4.

   Note: 394-1138 Transmission Ar does not have FORWARD 3 or REVERSE 3.

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

10. Repeat Steps 5 through 8.

High Idle Pressure Checks

1. Set the input flow to 189 ± 8 L/min (50 ± 2 US gpm).

2. Adjust the input rotation to 700 ± 20 rpm.

3. Adjust Tooling (Q) until a split flow of 91 ± 4 L/min (24 ± 1 US gpm) for controls and 98 ± 8 L/min (26 ± 2 US gpm) for TC (in) is achieved.

4. Shift the transmission to FORWARD 1 and increase input rotation to 2100 ± 20 rpm.

5. Record Lube Flow, Lube, Main Relief, TC (in), TC (out) pressures, and Horse Power Loss in Table 19.

6. Confirm values with Table 17 and 18.

7. Record all Clutch pressures in Table 22.

8. Confirm values with Table 20 and 21.

9. Shift transmission through FORWARD 2, FORWARD 3, FORWARD 4, REVERSE 1, REVERSE 2, REVERSE 3, and REVERSE 4.

   Note: 394-1138 Transmission Ar does not have FORWARD 3 or REVERSE 3.

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

10. Repeat Steps 2 through 8.

Speed Sensor Test

1. Set the input flow to 106 ± 8 L/min (28 ± 2 US gpm).

2. Adjust the input speed to 700 ± 20 rpm.

3. Adjust Tooling (Q) until a split flow of 45 ± 4 L/min (12 ± 1 US gpm) for controls and 61 ± 8 L/min (16 ± 2 US gpm) for TC (in) is achieved.

4. Shift the transmission to FORWARD 2.

5. Record Output Speed 1, Output Speed 2, and TC Output Speed in Table 23.

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 24.

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

Transmission Bench Test Data Sheet

Harness Test

Start Checks

Torque Converter Block Check

Lube Circuit Check

Low Idle Pressure Checks

High Idle Pressure Checks

Speed Sensor Test

Contamination Control