- Transmission
- TA22 (S/N: XMB1-UP)
Introduction
Revision | Summary of Changes in M0069966 |
03 | Updated Introduction. |
Updated TA3 Navigation. | |
Added Note. | |
Updated Captions for Graphics 48 and 49. | |
02 | |
01 | New Document. |
© 2016 Caterpillar All Rights Reserved. This guideline 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 special instruction contains the necessary information that is required to bench 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.
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.
Machine Model | Transmission Arrangement |
---|---|
TA22 |
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 the test bench, use 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 used to compare values on portions of this transmission test. 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 | |
Link Bracket As | 3 | ||
Bolt | 3 | ||
Washer | 3 | ||
B | Mounting Plate | 2 | |
C | Load Binder Assembly | 3 | |
D(1) | Bolt | 1 | |
Washer | 1 | ||
Fabricated Spacer | 1 | ||
E(1) | Yoke Assembly | 1 | |
F | Input Adapter | 1 | |
G | Adapter Assembly | 1 | |
H | Adapter Assembly | 1 | |
J | Adapter Assembly | 1 | |
K | O-Ring Seal | 1 | |
Adapter | 1 | ||
Fitting Assembly (Plain) | 1 | ||
L | O-Ring Seal | 1 | |
Adapter | 1 | ||
Fitting Assembly (Plain) | 1 | ||
M | O-Ring Seal | 1 | |
Adapter | 1 | ||
Fitting Assembly (Plain) | 1 | ||
N | Nipple (Quick Disconnect) | 1 | |
Adapter | 1 | ||
P | Nipple (Quick Disconnect) | 1 | |
Q | Nipple (Quick Disconnect) | 1 | |
Adapter | 1 | ||
R (2) | Cover | 1 | |
Nipple Quick Disconnect | 1 | ||
S(2) | Cover | 1 | |
Nipple Quick Disconnect | 1 | ||
T(2) | Cover | 1 | |
Nipple Quick Disconnect | 1 | ||
U | Transmission Analyzer Group | 1 | |
OR | |||
Transmission Analyzer Gp | 1 | ||
Adapter Cable Assembly (Transmission Analyzer) | 1 | ||
Cable (Test) | 1 | ||
Cable Adapter | 9 | ||
V | Multitach Tool Group | 1 | |
Adapter Cable Assembly (Speed Sensor) | 2 |
(1) | See Figure 3. |
(2) | See Figure 4. |
Illustration 3 | g01299757 |
Tooling (D) |
Illustration 4 | g01285710 |
Tooling (R), (S), and (T) |
Installation Procedure
- Install Tooling (A) to the front of the transmission.
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Illustration 6 g01288169 - Install Tooling (A) to the rear of the transmission.
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Illustration 7 g01288176 - Remove plug (1) from the front of the transmission oil sump.
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Illustration 8 g01288181 - Remove plug (2) from the rear of the transmission oil sump.
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Illustration 9 g01288182 - Install Tooling (B) to the rear of the transmission.
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Illustration 10 g01288186 - Install Tooling (B) to the front of the transmission.
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Illustration 11 g01288193 - Use a hoist to install the transmission on the test bench. The weight of the transmission is
1655.6 kg (3650 lb) .Show/hide tableIllustration 12 g01288201 - Install Tooling (C) to the front of the transmission on both sides.
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Illustration 13 g01288214 - Install Tooling (C) to the rear of the transmission.
Note: Over-tightening Tooling (C) can jeopardize the tightening ability of the castle nuts on Tooling (A) later in this section.
Show/hide tableIllustration 14 g01288313 - Install Tooling (D) into Tooling (E).
Note: For some transmissions, Tooling (D) may not be required. For the specifications regarding Tooling (D) and Tooling (E), refer to Figure 3.
Show/hide tableIllustration 15 g01288328 - Install Tooling (E) and Tooling (D) to the transmission input shaft.
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Illustration 16 g01288334 - Install Tooling (F) onto Tooling (E).
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Illustration 17 g01288337 - Install Tooling (G) onto Tooling (F).
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Illustration 18 g01288341 - Install Tooling (H) onto Tooling (G).
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Illustration 19 g01288345 - Install Tooling (J) onto Tooling (H).
Note: Tooling (J) is only required if the large drive shaft is being used. If the small drive shaft is being used, only Tooling (H) is required.
Show/hide tableIllustration 20 g01288352 - Align the transmission with the input shaft.
- Connect the input shaft to Tooling (J).
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Illustration 21 g01288360 - Install the drive shaft guard.
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Illustration 22 g03802221 - Tighten all four castle nuts and jack bolts.
- Tighten Tooling (C) to prevent movement of the transmission during testing.
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Illustration 23 g01288381 - Install Tooling (K).
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Illustration 24 g01288386 - Install Tooling (L).
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Illustration 25 g01288390 - Install Tooling (M).
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Illustration 26 g01288394 - Remove plug (3).
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Illustration 27 g01288398 - Install Tooling (N).
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Illustration 28 g01288400 - Remove plug (4).
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Illustration 29 g01288404 - Install Tooling (P).
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Illustration 30 g01288408 - Remove plug (5).
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Illustration 31 g01288411 - Install Tooling (Q).
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Illustration 32 g01288433 - Remove cover (6).
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Illustration 33 g01288472 - Install Tooling (R).
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Illustration 34 g01288477 - Remove cover (7).
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Illustration 35 g01288490 - Install Tooling (S).
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Illustration 36 g01288491 - Remove cover (8).
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Illustration 37 g01288493 - Install Tooling (T).
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Illustration 38 g01288494 (9) Charge Pump Supply - Connect hose assembly (9) from the pressurized flow meter to Tooling (K).
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Illustration 39 g01288626 (10) Cooler Inlet - Connect hose assembly (10) from Tooling (L) to the No. 2 flow meter inlet.
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Illustration 40 g01288630 (11) Lubrication Inlet - Connect hose assembly (11) from the No. two flow meter outlet to Tooling (M).
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Illustration 41 g01288649 (12) Lubrication Bypass Pressure - Connect pressure gauge (12) to Tooling (N).
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Illustration 42 g01288658 (13) Main Relief Valve Pressure - Connect pressure gauge (13) to Tooling (P).
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Illustration 43 g01288661 (14) Cooler Inlet Pressure - Connect a pressure gauge to pressure tap (14).
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Illustration 44 g01288634 (15) Input Shaft Pressure - Connect pressure gauge (15) to Tooling (Q).
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Illustration 45 g01288693 (16) Reverse Shaft Pressure - Connect pressure gauge (16) to Tooling (R).
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Illustration 46 g01288704 (17) Intermediate Shaft Pressure - Connect pressure gauge (17) to Tooling (S).
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Illustration 47 g01288707 (18) Centerline Shaft Pressure - Connect pressure gauge (18) to Tooling (T).
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Illustration 48 g01288712 (19) No. 9 Clutch
(20) No. 4 Clutch
(21) No. 3 Clutch
(22) No. 5 Clutch
(23) No. 2 Clutch
(24) No. 6 Clutch
(25) No. 1 Clutch
(26) No. 8 Clutch
(27) No. 7 Clutch - Connect the pressure gauges to the appropriate locations.
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Illustration 49 g01288737 (19) No. 9 Clutch / 9-I Harness Lead
(20) No. 4 Clutch / 4-D Harness Lead
(21) No. 3 Clutch / 3-C Harness Lead
(22) No. 5 Clutch / 5-E Harness Lead
(23) No. 2 Clutch / 2-B Harness Lead
(24) No. 6 Clutch / 6-F Harness Lead
(25) No. 1 Clutch / 1-A Harness Lead
(26) No. 8 Clutch / 8-H Harness Lead
(27) No. 7 Clutch / 7-G Harness Lead - Connect Tooling (U) to the appropriate solenoid.
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Illustration 50 g01288749 - Connect Tooling (U) to an appropriate location.
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Illustration 51 g01288753 Tooling (U) Show/hide tableIllustration 52 g01457869 Tooling (U) - Connect Tooling (U) to a power source.
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Illustration 53 g06064514 (28) Output Speed Sensor "A"
(29) Output Speed Sensor "B"Show/hide tableIllustration 54 g01285713 - Connect Tooling (V) to output speed sensors "A" and "B".
Illustration 5 | g01288157 |
TA3 Navigation
- Select “Challenger”.
- Select “MT800 - 12V”.
Note: Checking 4 Forward and 4 Reverse gears covers all solenoids.
Harness Test (TA3 only)
- Make sure that the Tooling (U) is properly connected to the transmission.
- Use Tooling (U) to perform the harness test.
- Record the values in Table 6.
Note: Do not continue testing until Harness Test passes.
Solenoid Test (TA2 only)
- Make sure that the Tooling (U) is properly connected to the transmission.
- Use Tooling (U) to perform the solenoid test.
- Record the values in Table 6.
Note: Do not continue testing until Solenoid 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 supply flow to
146 L/min (39 US gpm) .Show/hide tableIllustration 55 g02720621 - With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust input speed to 700 ± 10 rpm.
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.
- The lubrication pressure must be a minimum of
103 kPa (15 psi) .Note: If there is no lube pressure after 30 seconds, stop input rotation and check connections on test bench and transmission.
- Record the lubrication pressure in Table 8.
- Shift the transmission through all gears to eliminate air from the transmission controls.
- 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 Cl 7 Cl 8 Cl 9 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 - With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 10 rpm.
- Record the supply flow, charge pressure, lubrication flow, lubrication pressure, and output speed in Table 8.
Note: Tooling (U) has been programmed to ensure that the transmission is shifted sequentially into gear ranges. The functionality of some of the input keys has been changed to ensure the requirements of this procedure. Refer to Special Instruction, "Programming Features" for further Information.
- Verify all test points with the values in Table 7.
- Stop the input rotation.
High Idle Checks
- Adjust the inlet flow to
146 L/min (39 US gpm) . - Adjust the input rotation to 2100 ± 10 rpm in the NEUTRAL position.
- Record the pressures for the active clutches in Table 10.
- Verify all test points with the values in Table 9.
- Record the values in Table 12 for charge pressure, cooler flow, lubrication pressure, clutch leakages, shaft pressures, and output speed.
Note: Calculate clutch leakage by subtracting cooler flow from supply flow.
- Verify the test points with the values in Table 11.
- Adjust input speed to 700 ± 10 rpm.
- Shift the transmission through each FORWARD and REVERSE speed range. Repeat steps 2 through 7 for each gear range.
Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.
- Adjust the input rotation to 1000 ± 10 rpm.
- Stop the input rotation.
Lubrication Bypass Check
- Adjust the inlet flow to
146 L/min (39 US gpm) . - Adjust the input rotation to 2100 ± 10 rpm.
- Slowly adjust the oil supply to
215 L/min (57 US gpm) . At the same time, monitor the lubrication bypass pressure. - The lubrication bypass pressure should stabilize at
275 ± 34 kPa (40 ± 5 psi) . - Record the values in table 14.
- Verify the test points with the values in Table 13.
- Stop the input rotation.
Cooler Bypass Check
- Adjust the inlet flow to
146 L/min (39 US gpm) . - Adjust the input rotation to 2100 ± 10 rpm.
- Slowly increase the restriction at the No. 2 flow meter by adjusting the flow meter load valve clockwise until the cooler bypass pressure stabilizes.
- The cooler bypass pressure should Stabilize at
34 kPa (75 ± 5 psi) . - Record the values in table 16.
- Verify the test points with the values in Table 15.
- Stop the 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
CATERPILLAR | Transmission Bench Test Data Sheet | Test Date:_______ |
Model:_______ | ||
Work Order:_______ | Serial No.:_______ |
Solenoid Test
Solenoid Test | Solenoid 1 | Solenoid 2 | Solenoid 3 | Solenoid 4 | Solenoid 5 | Solenoid 6 | Solenoid 7 | Solenoid 8 | Solenoid 9 |
______
ohms |
______
ohms |
______
ohms |
______
ohms |
______
ohms |
______
ohms |
______
ohms |
______
ohms |
______
ohms |
Start Checks
Start Checks | |||||
---|---|---|---|---|---|
Pump Flow And Pressures | Input Speed (700 ± 10 rpm)
Input Flow |
||||
Gear | Supply Flow | Charge Pressure | Lubrication Flow | Lubrication Pressure | Output Speed |
N | |
|
|
|
0 rpm |
Start Checks | |||||
Pump Flow And Pressures | Input Speed (700 ± 10 rpm)
Input Flow |
||||
Oil Temperature | _______°C _______(°F) |
||||
Gear | Supply Flow | Charge Pressure | Lubrication Flow | Lubrication Pressure | Output Speed |
N | ______________ |
______________ |
______________ |
______________ |
______________ |
Clutch Pressure Check
Clutch Pressures | |||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|
Gear | Engaged Clutches | Cl 1 | Cl 2 | Cl 3 | Cl 4 | Cl 5 | Cl 6 | Cl 7 | Cl 8 | Cl 9 | |
N | - | 8 | |
||||||||
F1 | 1 | 5 | |
|
|||||||
F2 | 2 | 5 | |
|
|||||||
F3 | 3 | 5 | |
|
|||||||
F4 | 4 | 5 | |
|
|||||||
R1 | 5 | 9 | |
|
|||||||
R2 | 6 | 9 | |
|
|||||||
R3 | 7 | 9 | |
|
|||||||
R4 | 8 | 9 | |
|
Clutch Pressures | Input Speed (2100 ± 10 rpm)
Input Flow |
||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|
Gear | Engaged Clutches | Cl 1 | Cl 2 | Cl 3 | Cl 4 | Cl 5 | Cl 6 | Cl 7 | Cl 8 | Cl 9 | |
N | - | 8 | _____ | ||||||||
F1 | 1 | 5 | _____ | _____ | |||||||
F2 | 2 | 5 | _____ | _____ | |||||||
F3 | 3 | 5 | _____ | _____ | |||||||
F4 | 4 | 5 | _____ | _____ | |||||||
R1 | 5 | 9 | _____ | _____ | |||||||
R2 | 6 | 9 | _____ | _____ | |||||||
R3 | 7 | 9 | _____ | _____ | |||||||
R4 | 8 | 9 | _____ | _____ |
High Idle Check
High Idle Checks | Input Speed (2100 ± 10 rpm)
Input Flow |
|||||||
---|---|---|---|---|---|---|---|---|
Gear | Supply Flow | Charge Pressure
kPa (psi) |
Cooler Flow
L/min (gpm) |
Lubrication Pressure
kPa (psi) |
Leakage | |||
N | |
|
|
|
|
|||
F1 | ||||||||
F2 | ||||||||
F3 | ||||||||
F4 | ||||||||
R1 | ||||||||
R2 | ||||||||
R3 | ||||||||
R4 | ||||||||
Gear | Input Shaft Lubrication
kPa (psi) |
Reverse Shaft Lubrication
kPa (psi) |
Intermediate Shaft Lubrication
kPa (psi) |
Centerline Shaft Lubrication
kPa (psi) |
Output Speed (rpm) | |||
N | |
|
|
|
0 | |||
F1 | |
|
|
|
249 | |||
F2 | |
|
|
|
315 | |||
F3 | |
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|
|
400 | |||
F4 | |
|
|
|
507 | |||
R1 | |
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|
|
200 | |||
R2 | |
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|
|
486 | |||
R3 | |
|
|
|
548 | |||
R4 | |
|
|
|
1330 |
High Idle Checks | Input Speed (2100 ± 10 rpm)
Input Flow |
||||
---|---|---|---|---|---|
Gear | Supply Flow | Charge Pressure
kPa (psi) |
Cooler Flow
L/min (gpm) |
Lubrication Pressure
kPa (psi) |
Leakage |
N | |||||
F1 | |||||
F2 | |||||
F3 | |||||
F4 | |||||
R1 | |||||
R2 | |||||
R3 | |||||
R4 | |||||
Gear | Input Shaft Lubrication
kPa (psi) |
Reverse Shaft Lubrication
kPa (psi) |
Intermediate Shaft Lubrication
kPa (psi) |
Output Shaft Lubrication
kPa (psi) |
Output Speed |
N | |||||
F1 | |||||
F2 | |||||
F3 | |||||
F4 | |||||
R1 | |||||
R2 | |||||
R3 | |||||
R4 |
Lubrication Bypass Check
Lubrication Bypass | |
---|---|
Lubrication Bypass Pressure | |
Lubrication Bypass Check
|
_______kPa _______(psi) |
Cooler Bypass Check
Cooler Bypass | |
---|---|
Cooler Bypass Pressure | |
Cooler Bypass Check
|
_______kPa _______(psi) |
Contamination Control
ISO Particle Count | Sample the test bench oil supply. *ISO 4406 is 16/13 or better |
________/________Particle Count |
______________________________________ Technician |
______________________________________ Supervisor |