Bench Test Procedure for a 14L, 120M, 120M Series 2, 12M, 12M Series 2, 12M Series 3, 140M, 140M Series 2, 140M Series 3, 160M, 160M Series 2, and 160M Series 3 Motor Grader Transmission {3030, 3073} Caterpillar

Bench Test Procedure for a 14L, 120M, 120M Series 2, 12M, 12M Series 2, 12M Series 3, 140M, 140M Series 2, 140M Series 3, 160M, 160M Series 2, and 160M Series 3 Motor Grader Transmission {3030, 3073} [REHS3458]

POWER TRAIN

CONTROL GP-TRANSMISSION HYD

Bench Test Procedure for a 14L, 120M, 120M Series 2, 12M, 12M Series 2, 12M Series 3, 140M, 140M Series 2, 140M Series 3, 160M, 160M Series 2, and 160M Series 3 Motor Grader Transmission {3030, 3073}

1.1. Introduction

2.1. Canceled Part Numbers and Replaced Part Numbers

3.1. Important Safety Information

4.1. Collecting The Test Data

5.1. Tools Needed

6.1. FT Drawings

7.1. Installation Procedure

8.1. Test Procedure

9.2. Harness Test

10.2. Start Checks

11.2. Pressure Check (Low Idle)

12.2. Clutch Engagement Pressure Check (Low Idle)

13.2. Pressure Check (High Idle)

14.2. Clutch Engagement Pressure Check (High Idle)

15.2. Lube Bypass Check

16.2. Cooler Bypass Check

17.2. Contamination Control

18.1. Transmission Bench Test Data Sheet

19.2. Harness Test

20.2. Pressure Check (Low Idle)

21.2. Pressure Check (Low Idle)

22.2. Clutch Engagement Pressure Check (Low Idle)

23.2. Pressure Check (High Idle)

24.2. Pressure Check (High Idle)

25.2. Clutch Engagement Pressure Check (High Idle)

26.2. Lube Bypass Check

27.2. Cooler Bypass Check

28.2. Contamination Control

Motor Grader
120M (S/N: B9C1-UP; B9N1-UP; B9W1-UP; D9W1-UP)
120M Series 2 (S/N: M9C1-UP; M9H1-UP; R9N1-UP; R9W1-UP)
12M (S/N: B921-UP; B9F1-UP; B9R1-UP)
12M Series 2 (S/N: F9B1-UP; F9M1-UP; R9P1-UP; R9S1-UP)
12M Series 3 (S/N: N9B1-UP; N9F1-UP; N9P1-UP; N9R1-UP)
12M Series II (S/N: M9F1-UP)
140 (S/N: N941-UP; N951-UP)
140M (S/N: B9D1-UP; B9G1-UP; D9G1-UP; B9M1-UP)
140M Series 2 (S/N: M9D1-UP; R9G1-UP; M9J1-UP; R9M1-UP)
140M Series 3 (S/N: N9D1-UP; N9G1-UP; N9J1-UP; N9M1-UP)
14L (S/N: B941-UP)
160M (S/N: B9E1-UP; B9L1-UP; B9T1-UP; D9T1-UP)
160M Series 2 (S/N: M9E1-UP; M9K1-UP; R9L1-UP; R9T1-UP)
160M Series 3 (S/N: N9E1-UP; N9K1-UP; N9L1-UP; N9T1-UP)

Introduction

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Table 1
Revision	Summary of Changes in REHS3458
17	Added Model 140 to the Title and Serial Number Prefixes N94 and N95.Updated Table 2.
16	Updated Installation Procedure photos.Updated Test Procedures and Tables.
15	Added serial number prefixes. Updated Table 2.
14	Updated Table 3.
13	Removed references to Cooler Flows throughout document.

© 2018 AVSpare All Rights Reserved. This document 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 AVSpare: 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 AVSpare. 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 AVSpare..

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.

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Table 2
Machine Model	Transmission Arrangement
14L	396-3303
12M	253-8405, 370-6589
12M Series 2	331-5225, 364-8476, 396-3357
12M Series 3	396-3303, 381-0660
120M	253-8405
120M Series 2	331-5225, 253-8405
140M	253-8405
140M Series 2	331-5225, 253-8405, 364-8476
140M Series 3	396-3303, 381-0660
160M	253-8405
160M Series 2	331-5225, 253-8405, 364-8476
160M Series 3	396-3303, 381-0660
140	517-8360

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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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 AVSpare products. These warnings should be observed before performing any procedures. AVSpare 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.

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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.

AVSpare 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. AVSpare 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 were used to develop this test procedure.

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Table 3
Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9584	Rail As	2
	439-5592⁽¹⁾	Rail As	2
	1U-9585	Block Gp (Transmission Mounting)	1
	FT-2277	Support	1
	6V-5685	Bolt (M14X2.00X50 mm)	1
	421-5663	Lifting Eye Assembly	2
B	136-3648	Adapter As	1
C	1U-9131	Drive Adapter (Key)⁽²⁾	1
C	1U-9359	Drive Adapter⁽³⁾	1
D	4C-4701	Spindle Adapter	1
	2J-5245	Bolt (3/8-16X1.25 inch)	4
	4B-4278	Washer	4
E	369-5916	Lifting Eye Assembly	2
E	1U-9722	Load Binder As (Ratchet Type)	3
F⁽⁴⁾	156-1153	Dust Cap	1
	6V-5218	Bolt (M8X1.25X35 mm)	1
	9M-1974	Hard Washer	1
G	6V-3965	Fitting	1
G	3J-1907	O-Ring Seal	1
H	5P-8905	O-Ring Adapter	1
	2S-4078	O-Ring Seal	1
	5P-4674	O-Ring Adapter	1
	3E-6769	O-Ring Seal	1
	5P-4675	Adapter	1
	5P-7814	O-Ring Seal	1
	6V-3966	Fitting As	1
J	9X-2101	Elbow	1
J	8C-9024	Fitting As	1
K	120-6843	Ball Valve	1
	144-8618	Adapter	1
	8C-9025	Quick Coupler	1
	8C-9024	Fitting As	1
L	5P-0492	Adapter	1
	5P-7701	O-Ring Seal	1
	8C-9024	Fitting As	1
M	1U-9869	Flange	2
	3E-6746	O-Ring Seal	1
	8T-9515	Bolt (M10x1.5x40mm)	4
		Bushing	1
	8C-9024	Fitting As	1
N	6V-3965	Fitting	2
N	3J-1907	O-Ring Seal	2
P	9U-7444	Adapter As	1
	1U-8304	Fitting	1
	9U-7446	Adapter	1
	1P-4577	Half Flange	2
	8C-9024	Nipple (Plain)	1
	6V-3965	Nipple (Quick Disconnect)	1
	6V-1820	Bolt (M10X1.50X30 mm)	4
	8T-4896	Hard Washer	4
Q	122-6908	Hydraulic Hose	1
	1H-2815	Pipe Nipple	1
	140-9462	Reducer Bushing	1
	1U-9875	Coupler	1
	9U-7024	Adapter	1
	5P-0597	Hose Clamp	1
R	5P-7701	O-Ring Seal	1
	5P-0492	Adapter	1
	8C-9024	Nipple (Plain)	1
S	2S-4078	O-Ring Seal	1
	5P-8905	O-Ring Adapter	1
	3E-6769	O-Ring Seal	1
	5P-4674	O-Ring Adapter	1
	5P-7814	O-Ring Seal	1
	5P-4675	O-Ring Adapter	1
	6V-3966	Nipple (Quick Disconnect)	1
T⁽⁵⁾	9W-1454	Cover	1
	6V-3966	Nipple (Quick Disconnect)	1
	5P-5863	O-Ring Seal	1
U	085-7356	Fitting	1
	2P-8421	O-Ring Adapter	1
	6V-3965	Fitting	1
V	6V-7483	Adapter	1
	9B-3523	Bushing	1
	3D-8884	Elbow	1
	6V-3966	Fitting As	1
W	306-0397	Extension Cable	1
	306-6388⁽⁶⁾	Adapter Cable As	1
	460-2395⁽⁷⁾	Adapter Harness As	1
	FT-3222⁽⁸⁾	Adapter Harness As	1
X	277-2363	Transmission Analyzer Gp	1
Y	4C-9910	Portable Hydraulic Tester	2
Z	8T-0855	Pressure Gauge ( 0 - 4000kPa (0 - 580 psi))	12
Z	6V-4144	Quick Connect Coupler	12
AA	8T-0854	Pressure Gauge ( 0 - 965 kPa (0 - 140 psi))	7
AA	6V-4144	Quick Connect Coupler	7

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⁽¹⁾	Use if test bed platform is flush with the floor.
⁽²⁾	This drive adapter is used with the small drive shaft.
⁽³⁾	This drive adapter is used with the large drive shaft.
⁽⁴⁾	Refer to Illustration 3.
⁽⁵⁾	Refer to Illustration 4.
⁽⁶⁾	For use with M Series 1.
⁽⁷⁾	For use with M Series 2.
⁽⁸⁾	For use with M Series 3.

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Illustration 3	g01393792

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Illustration 4	g01393793

FT Drawings

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Illustration 5	g03831077
FT-2277

Installation Procedure

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Illustration 6	g03735388

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Illustration 7	g03735397

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Illustration 8	g01393787

Install Tooling (A) onto the test bench and transmission.
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Illustration 9 g01395573
Use a hoist to install the transmission on the test bench. The weight of the transmission is 1043 kg (2300 lb).
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Illustration 10 g03735423
Remove cover (1).
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Illustration 11 g03735427
Install Tooling (B).
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Illustration 12 g03735456
Install tooling (C) on Tooling (B).
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Illustration 13 g03735477
Install Tooling (D) onto the transmission and slide Tooling (A) towards the drive shaft guard to align with the drive shaft.
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Illustration 14 g03735524
Connect the drive shaft to Tooling (D).
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Illustration 15 g03735538
Close and latch drive shaft guard.
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Illustration 16 g03735542
Tighten all four castle nuts and jack bolts.
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Illustration 17 g03735570
Install Tooling (E) to prevent movement during testing.
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Illustration 18 g03738605
Remove yoke assembly (2) from the transmission.
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Illustration 19 g03738609
Remove dust cap (3) from yoke assembly (2).
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Illustration 20 g03738617
Install Tooling (F) to yoke assembly (2).
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Illustration 21 g03735594
Install yoke assembly (2) to the transmission output shaft.
Note: The 156-1153 dust cap must be replaced with a dust cap that is not modified after testing is complete. Replace this cap before the machine is returned to service.
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Illustration 22 g03735849
Remove Plug (4).
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Illustration 23 g03735878
Install Tooling (G).
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Illustration 24 g03735883

Six ports
Remove covers/plugs (5).
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Illustration 25 g03735907
Install Tooling (H).
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Illustration 26 g03735937
Install Tooling (J).
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Illustration 27 g03735948
Install Tooling (K) onto Tooling (J).
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Illustration 28 g03735975
Install Tooling (L).
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Illustration 29 g03736018
Install Tooling (M).
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Illustration 30 g03736039
Install Tooling (N).
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Illustration 31 g03736090
Remove cover (6)
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Illustration 32 g03736106
Install Tooling (P).
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Illustration 33 g03736071
Install Tooling (Q).
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Illustration 34 g03736126
Remove plug (7).
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Illustration 35 g03736133
Install Tooling (R).
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Illustration 36 g03736146
Remove cover (8).
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Illustration 37 g03736162
Install Tooling (S).
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Illustration 38 g03736173
Remove cover (9).
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Illustration 39 g03736164
Install Tooling (T).
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Illustration 40 g03736120
Remove plug (10).
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Illustration 41 g03736182
Install Tooling (U).
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Illustration 42 g03736180
Remove plug (11).
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Illustration 43 g03736403
Install Tooling (V).
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Illustration 44 g03736429

Suction Oil Supply
Connect Hose Assembly (12) from Gravity Feed to Tooling (Q).
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Illustration 45 g03736549

Transmission Scavenge Oil
Connect Hose Assembly (13) from Tooling (P) to the oil drain.
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Illustration 46 g03736576

Transmission Pump Flow
Connect Hose Assembly (14) from Tooling (R) to Flowmeter 1 (in).
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Illustration 47 g03736625

Controls (in)
Connect Hose Assembly (15) from Flowmeter 1 (out) to Tooling (M).
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Illustration 48 g03736637

Controls (out)
Connect Hose Assembly (16) from Tooling (L) to Flowmeter 2 (in).
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Illustration 49 g03736638

Lube (in)
Connect Hose Assembly (17) from Flowmeter 2 (out) to Tooling (K).
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Illustration 50 g03736642

0 - 4000 kPa (0 - 580 psi)
(18) Parking Break Pressure
Connect a pressure gauge to pressure tap (18).
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Illustration 51 g03736646

0 - 965 kPa (0 - 140 psi)
(19) Flywheel Lube Pressure
Connect a pressure gauge to pressure tap (19).
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Illustration 52 g03736673

0 - 4000 kPa (0 - 580 psi)
(20) Differential Lock Pressure
Connect a pressure gauge to pressure tap (20).
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Illustration 53 g03736688

0 - 965 kPa (0 - 140 psi)
(21) Lube Relief Pressure
Connect a pressure gauge to pressure tap (21).
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Illustration 54 g03737630

0 - 4000 kPa (0 - 580 psi)
(22) Main Relief Pressure
Connect a pressure gauge to pressure tap (22).
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Illustration 55 g03737644

0 - 965 kPa (0 - 140 psi)
(23) Input Shaft Lube Pressure
Connect a pressure gauge to pressure tap (23).
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Illustration 56 g03737652

0 - 965 kPa (0 - 140 psi)
(24) Shaft 3 Lube Pressure
Connect a pressure gauge to pressure tap (24).
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Illustration 57 g03737668

0 - 965 kPa (0 - 140 psi)
(25) Shaft 2 Lube Pressure
Connect a pressure gauge to pressure tap (25).
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Illustration 58 g03737688

0 - 965 kPa (0 - 140 psi)
(26) Shaft 4 Lube Pressure
Connect a pressure gauge to pressure tap (26).
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Illustration 59 g03737696

0 - 965 kPa (0 - 140 psi)
(27) Output Shaft Lube Pressure
Connect a pressure gauge to pressure tap (27).
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Illustration 60 g03738600

0 - 4000 kPa (0 - 580 psi)
(28) Pump Pressure

Connect a pressure gauge to pressure tap (28).

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Illustration 61	g03737722
0 - 4000 kPa (0 - 580 psi) (29) Clutch No. 1 (30) Clutch No. 2 (31) Clutch No. 3 (32) Clutch No. 4 (33) Clutch No. 5 (34) Clutch No. 6 (35) Clutch No. 7 (36) Clutch No. 8

Connect a pressure gauges to pressure taps (29 - 36).
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Illustration 62 g03738585
Install Tooling (W).
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Illustration 63 g03738594
Connect Tooling (W) to Tooling (X).

Test Procedure

Harness Test

Make sure that the Tooling (W) is properly connected.
Use Tooling (X) to perform the harness test.
Record the values in Table 7.

Start Checks

Refer to Testing and Adjusting, RENR8454, "140M and 160M Motor Graders Power Train" for the correct adjusting procedures.

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 64 g02720621

Test Bench Rotation Direction
With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 800 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.
Note: An input speed of at least 800 rpm must be maintained for the duration of the test. This speed will prevent the engagement of the parking brake.
Check the Pump Flow and the Main Relief Pressure. Compare the results with Table 4.
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Table 4
Start Checks Input Speed (800 rpm)

Pump Flow 49 ± 6 L/min (13 ± 1.5 US gpm)

Main Relief Pressure 2482 ± 69 kPa (360 ± 10 psi)
Shift the transmission through all gears to eliminate air from the transmission controls.
Check for lockup or excessive drag in all gears.

Confirm the correct clutch engagement with Table 5.

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Table 5
Clutch Engagement Check
Gear	Cl 1	Cl 2	Cl 3	Cl 4	Cl 5	Cl 6	Cl 7	Cl 8
N					X			X
P					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

Stop the input rotation.

Pressure Check (Low Idle)

Adjust the input rotation to 800 rpm.
Shift the transmission to the PARK position.
Record Pump Flow, Input Shaft Pressure, Shaft 2 Pressure, Shaft 3 Pressure, Shaft 4 Pressure, Output Shaft Pressure, Inlet Relief Pressure, Parking Brake Pressure, Differential Lock Pressure, Flywheel Lubrication Pressure, and Pump Pressure in Table 9 or Table 10.
Shift the transmission through ranges FORWARD 1, FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, FORWARD 7, FORWARD 8, NEUTRAL, REVERSE 1, REVERSE 2, REVERSE 3, REVERSE 4, REVERSE 5, and REVERSE 6. Repeat Step 3 for each gear range.
Note: Always shift back to NEUTRAL when shifting between FORWARD and REVERSE.
Shift the transmission to the NEUTRAL position.
Stop the input rotation.
Verify that all values match the specifications in Table 8.

Clutch Engagement Pressure Check (Low Idle)

Adjust the input rotation to 800 rpm.
Shift the transmission to the PARK position.
Record the pressures of the activated clutches in Table 12.
Shift the transmission through ranges FORWARD 1, FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, FORWARD 7, FORWARD 8, NEUTRAL, REVERSE 1, REVERSE 2, REVERSE 3, REVERSE 4, REVERSE 5, and REVERSE 6. Repeat Step 3 for each gear range.
Note: Always shift back to NEUTRAL when shifting between FORWARD and REVERSE.
Shift the transmission to the NEUTRAL position.
Stop the input rotation.
Verify that all values match the specifications in Table 11 or are within 69 kPa (10 psi) of Main Relief Pressure.

Pressure Check (High Idle)

Adjust the input speed to 800 rpm.
Shift the transmission to the PARK position.
Adjust the input rotation to 2100 rpm.
Record Pump Flow, Input Shaft Pressure, Shaft 2 Pressure, Shaft 3 Pressure, Shaft 4 Pressure, Output Shaft Pressure, Inlet Relief Pressure, Parking Brake Pressure, Lube Relief Pressure, Differential Lock Pressure, Flywheel Lubrication Pressure, and Pump Pressure in Table 14 or Table 15.
Return the input speed to 800 rpm.
Shift the transmission through ranges Forward 1, Forward 2, Forward 3, Forward 4, Forward 5, Forward 6, Forward 7, Forward 8, Neutral, Reverse 1, Reverse 2, Reverse 3, Reverse 4, Reverse 5, and Reverse 6. Repeat Step 3 through Step 5 for each gear range.
Note: Always shift back to NEUTRAL when shifting between FORWARD and REVERSE.
Shift the transmission to the NEUTRAL position.
Stop the input rotation.
Verify that all values match the specifications in Table 13.

Clutch Engagement Pressure Check (High Idle)

Adjust the input rotation to 800 rpm.
Shift the transmission to the PARK position.
Adjust the input rotation to 2100 rpm.
Record the pressures of the activated clutches in Table 17.
Return the input rotation to 800 rpm.
Shift the transmission through ranges FORWARD 1, FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, FORWARD 7, FORWARD 8, NEUTRAL, REVERSE 1, REVERSE 2, REVERSE 3, REVERSE 4, REVERSE 5, and REVERSE 6. Repeat Step 3 through Step 5 for each gear range.
Note: Always shift back to NEUTRAL when shifting between FORWARD and REVERSE.
Shift the transmission to the NEUTRAL position.
Stop the input rotation.
Verify that all values match the specifications in Table 16 or are within 69 kPa (10 psi) of Main Relief Pressure.

Lube Bypass Check

Shift the transmission to the NEUTRAL position.
Slowly adjust the input rotation from 800 rpm toward 2100 rpm.
Watch for Lube Pressure to stop increasing as input rotation increases.
Lube bypass should occur at 517 ± 34 kPa (75 ± 5 psi).
Record the Lube Bypass Pressure and input rotation in Table 18.

Cooler Bypass Check

Shift the transmission to the NEUTRAL position.
Adjust the input speed from 800 rpm to 2100 rpm.
Use Tooling (K) to slowly restrict Cooler Flow (Lube In) until Cooler Flow (Lube In) starts to drop.
Cooler bypass should occur at a delta pressure of 517 ± 34 kPa (75 ± 5 psi) (Cooler Pressure — Lube Pressure).
Note: Bypass may not occur at the cracking of the bypass valve. You may need to close Tooling (K) more to achieve full shifting of bypass valve.
Record and verify Pump Flow, Lube Flow (Cooler Flow), Cooler Bypass Valve Pressure in Table 19.
Open Tooling (K).
Stop the input rotation.

Contamination Control

Take an oil sample of the test bench oil supply. Oil contamination sample must meet ISO 16/13 standards.
Record the results in Table 20.
Remove the transmission from the test bench if the test bench oil supply is within specifications.

Transmission Bench Test Data Sheet

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Table 6
AVSpare	Transmission Bench Test Data Sheet	Test Date:_______
		Model:_______
Work Order:_______		Serial No.:_______

Harness Test

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Table 7
Solenoid Test	Solenoid 1	Solenoid 2	Solenoid 3	Solenoid 4	Solenoid 5	Solenoid 6	Solenoid 7	Solenoid 8
Solenoid Test	ohms	ohms	ohms	ohms	ohms	ohms	ohms	ohms

Pressure Check (Low Idle)

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Table 8
Pressure Check Forward (Low Idle) Input Speed (800 rpm)
			Forward								Reverse
Gear	P	N	1	2	3	4	5	6	7	8	1	2	3	4	5	6
Pump Flow	49 ± 6 L/min (13 ± 1.5 US gpm)
Lube Flow	34 ± 7.6 L/min (9 ± 2 US gpm)
Shaft 2 Press.	13.8 kPa (2.0 psi) Minimum		24 ± 24 kPa (3.5 ± 3.5 psi)
Shaft 3 Press.	13.8 kPa (2.0 psi) Minimum		24 ± 24 kPa (3.5 ± 3.5 psi)
Shaft 4 Press.	13.8 kPa (2.0 psi) Minimum		24 ± 24 kPa (3.5 ± 3.5 psi)
Output Shaft Press.	13.8 kPa (2.0 psi) Minimum		24 ± 24 kPa (3.5 ± 3.5 psi)
Inlet Relief Press.	2482 ± 69 kPa (360 ± 10 psi)
Parking Brake Press.	0.0 kPa (0.0 psi)	2482 ± 69 kPa (360 ± 10 psi)
Diff. Lock Press.	2516.6 ± 68.9 kPa (365.0 ± 10 psi)	Within 69 kPa (10 psi) of Inlet Relief Pressure
Pump Press.	2654.5 ± 69.8 kPa (385.0 ± 10.0 psi)	2482 ± 69 kPa (360 ± 10 psi)

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Table 9
Pressure Check Forward (Low Idle) Input Speed (800 rpm)
Gear	N	1F	2F	3F	4F	5F	6F	7F	8F
Pump Flow	_____	_____	_____	_____	_____	_____	_____	_____	_____
Lube Flow	_____	_____	_____	_____	_____	_____	_____	_____	_____
Shaft 2 Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____
Shaft 3 Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____
Shaft 4 Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____
Output Shaft Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____
Inlet Relief Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____
Parking Brake Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____
Diff. Lock Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____
Pump Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____

Pressure Check (Low Idle)

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Table 10
Pressure Check Reverse (Low Idle) Input Speed (800 rpm)
Gear	P	1R	2R	3R	4R	5R	6R
Pump Flow	_____	_____	_____	_____	_____	_____	_____
Lube Flow	_____	_____	_____	_____	_____	_____	_____
Shaft 2 Press.	_____	_____	_____	_____	_____	_____	_____
Shaft 3 Press.	_____	_____	_____	_____	_____	_____	_____
Shaft 4 Press.	_____	_____	_____	_____	_____	_____	_____
Output Shaft Press.	_____	_____	_____	_____	_____	_____	_____
Inlet Relief Press.	_____	_____	_____	_____	_____	_____	_____
Parking Brake Press.	_____	_____	_____	_____	_____	_____	_____
Diff. Lock Press.	_____	_____	_____	_____	_____	_____	_____
Pump Press.	_____	_____	_____	_____	_____	_____	_____

Clutch Engagement Pressure Check (Low Idle)

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Table 11
Gear	Clutches Engaged
	Direction			Speed			Range
	FWD HI	FWD LO	REV	2ND	3RD	1ST	LO	HI
	1	2	3	4	5	6	7	8
Park	X	X	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)
N	X	X	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)
1F	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	X	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X
2F	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X
3F	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X
4F	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X
5F	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	X	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)
6F	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)
7F	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)
8F	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)
1R	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X
2R	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X
3R	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X
4R	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)
5R	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)
6R	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)	X	X	2482.1 ± 68.9 kPa (360.0 ± 10.0 psi)

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Table 12
Gear	Clutches Engaged
	Direction			Speed			Range
	FWD HI	FWD LO	REV	2ND	3RD	1ST	LO	HI
	1	2	3	4	5	6	7	8
Park	X	X	X	X	_____	X	X	_____
Neutral	X	X	X	X	_____	X	X	_____
1F	_____	X	X	X	X	_____	_____	X
2F	X	_____	X	_____	X	X	_____	X
3F	X	_____	X	X	_____	X	_____	X
4F	_____	X	X	X	_____	X	_____	X
5F	_____	X	X	X	X	_____	X	_____
6F	X	_____	X	_____	X	X	X	_____
7F	_____	X	X	_____	X	X	X	_____
8F	_____	X	X	X	_____	X	X	_____
1R	X	X	_____	X	X	_____	_____	X
2R	X	X	_____	_____	X	X	_____	X
3R	X	X	_____	X	_____	X	_____	X
4R	X	X	_____	X	X	_____	X	_____
5R	X	X	_____	_____	X	X	X	_____
6R	X	X	_____	X	_____	X	X	_____

Pressure Check (High Idle)

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Table 13
Pressure Check Forward (High Idle) Input Speed (2100 rpm)
			Forward								Reverse
Gear	P	N	1	2	3	4	5	6	7	8	1	2	3	4	5	6
Pump Flow	128 ± 6 L/min (34 ± 1.5 US gpm)
Lube Flow	117 ± 11 L/min (31 ± 3 US gpm)
Input Shaft Press.	517 ± 34 kPa (75 ± 5 psi)		100 ± 21 kPa (14.5 ± 3 psi)
Shaft 2 Press.	558 ± 69 kPa (81 ± 10 psi)		207 ± 69 kPa (30 ± 10 psi)
Shaft 3 Press.	558 ± 69 kPa (81 ± 10 psi)		207 ± 69 kPa (30 ± 10 psi)
Shaft 4 Press.	558 ± 69 kPa (81 ± 10 psi)		207 ± 69 kPa (30 ± 10 psi)
Output Shaft Press.	558 ± 69 kPa (81 ± 10 psi)		207 ± 69 kPa (30 ± 10 psi)
Inlet Relief Press.	2758 ± 69 kPa (400 ± 10 psi)
Parking Brake Press.	0.0 kPa (0.0 psi)	2758 ± 69 kPa (400 ± 10 psi)
Lube Relief Press.	551.5 ± 34.5 kPa (80.0 ± 5.0 psi)		276 ± 21 kPa (40 ± 3 psi)
Diff. Lock Press.	Within 69 kPa (10 psi) of Inlet Relief Pressure
Flywheel Lube Press.	827 ± 34 kPa (120 ± 5 psi)		483 ± 34 kPa (70 ± 5 psi)
Pump Press.	2758 ± 69 kPa (400 ± 10 psi)

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Table 14
Pressure Check Forward (High Idle) Input Speed (2100 rpm)
Gear	N	1F	2F	3F	4F	5F	6F	7F	8F
Pump Flow	_____	_____	_____	_____	_____	_____	_____	_____	_____
Lube Flow	_____	_____	_____	_____	_____	_____	_____	_____	_____
Input Shaft Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____
Shaft 2 Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____
Shaft 3 Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____
Shaft 4 Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____
Output Shaft Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____
Inlet Relief Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____
Parking Brake Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____
Lube Relief Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____
Diff. Lock Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____
Flywheel Lube Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____
Pump Press.	_____	_____	_____	_____	_____	_____	_____	_____	_____

Pressure Check (High Idle)

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Table 15
Pressure Check Reverse (High Idle) Input Speed (2100 rpm)
Gear	P	1R	2R	3R	4R	5R	6R
Pump Flow	_____	_____	_____	_____	_____	_____	_____
Lube Flow	_____	_____	_____	_____	_____	_____	_____
Input Shaft Press.	_____	_____	_____	_____	_____	_____	_____
Shaft 2 Press.	_____	_____	_____	_____	_____	_____	_____
Shaft 3 Press.	_____	_____	_____	_____	_____	_____	_____
Shaft 4 Press.	_____	_____	_____	_____	_____	_____	_____
Output Shaft Press.	_____	_____	_____	_____	_____	_____	_____
Inlet Relief Press.	_____	_____	_____	_____	_____	_____	_____
Parking Brake Press.	_____	_____	_____	_____	_____	_____	_____
Lube Relief Press.	_____	_____	_____	_____	_____	_____	_____
Diff. Lock Press.	_____	_____	_____	_____	_____	_____	_____
Flywheel Lube Press.	_____	_____	_____	_____	_____	_____	_____
Pump Press.	_____	_____	_____	_____	_____	_____	_____

Clutch Engagement Pressure Check (High Idle)

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Table 16
Gear	Clutches Engaged
	Direction			Speed			Range
	FWD HI	FWD LO	REV	2ND	3RD	1ST	LO	HI
	1	2	3	4	5	6	7	8
Park	X	X	X	X	2758 ± 69 kPa (400 ± 10 psi)	X	X	2758 ± 69 kPa (400 ± 10 psi)
N	X	X	X	X	2758 ± 69 kPa (400 ± 10 psi)	X	X	2758 ± 69 kPa (400 ± 10 psi)
1F	2758 ± 69 kPa (400 ± 10 psi)	X	X	X	X	2758 ± 69 kPa (400 ± 10 psi)	2758 ± 69 kPa (400 ± 10 psi)	X
2F	X	2758 ± 69 kPa (400 ± 10 psi)	X	2758 ± 69 kPa (400 ± 10 psi)	X	X	2758 ± 69 kPa (400 ± 10 psi)	X
3F	X	2758 ± 69 kPa (400 ± 10 psi)	X	X	2758 ± 69 kPa (400 ± 10 psi)	X	2758 ± 69 kPa (400 ± 10 psi)	X
4F	2758 ± 69 kPa (400 ± 10 psi)	X	X	X	2758 ± 69 kPa (400 ± 10 psi)	X	2758 ± 69 kPa (400 ± 10 psi)	X
5F	2758 ± 69 kPa (400 ± 10 psi)	X	X	X	X	2758 ± 69 kPa (400 ± 10 psi)	X	2758 ± 69 kPa (400 ± 10 psi)
6F	X	2758 ± 69 kPa (400 ± 10 psi)	X	2758 ± 69 kPa (400 ± 10 psi)	X	X	X	2758 ± 69 kPa (400 ± 10 psi)
7F	2758 ± 69 kPa (400 ± 10 psi)	X	X	2758 ± 69 kPa (400 ± 10 psi)	X	X	X	2758 ± 69 kPa (400 ± 10 psi)
8F	2758 ± 69 kPa (400 ± 10 psi)	X	X	X	2758 ± 69 kPa (400 ± 10 psi)	X	X	2758 ± 69 kPa (400 ± 10 psi)
1R	X	X	2758 ± 69 kPa (400 ± 10 psi)	X	X	2758 ± 69 kPa (400 ± 10 psi)	2758 ± 69 kPa (400 ± 10 psi)	X
2R	X	X	2758 ± 69 kPa (400 ± 10 psi)	2758 ± 69 kPa (400 ± 10 psi)	X	X	2758 ± 69 kPa (400 ± 10 psi)	X
3R	X	X	2758 ± 69 kPa (400 ± 10 psi)	X	2758 ± 69 kPa (400 ± 10 psi)	X	2758 ± 69 kPa (400 ± 10 psi)	X
4R	X	X	2758 ± 69 kPa (400 ± 10 psi)	X	X	2758 ± 69 kPa (400 ± 10 psi)	X	2758 ± 69 kPa (400 ± 10 psi)
5R	X	X	2758 ± 69 kPa (400 ± 10 psi)	2758 ± 69 kPa (400 ± 10 psi)	X	X	X	2758 ± 69 kPa (400 ± 10 psi)
6R	X	X	2758 ± 69 kPa (400 ± 10 psi)	X	2758 ± 69 kPa (400 ± 10 psi)	X	X	2758 ± 69 kPa (400 ± 10 psi)

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Table 17
Gear	Clutches Engaged
	Direction			Speed			Range
	FWD HI	FWD LO	REV	2ND	3RD	1ST	LO	HI
	1	2	3	4	5	6	7	8
Park	X	X	X	X	_____	X	X	_____
Neutral	X	X	X	X	_____	X	X	_____
1F	_____	X	X	X	X	_____	_____	X
2F	X	_____	X	_____	X	X	_____	X
3F	X	_____	X	X	_____	X	_____	X
4F	_____	X	X	X	_____	X	_____	X
5F	_____	X	X	X	X	_____	X	_____
6F	X	_____	X	_____	X	X	X	_____
7F	_____	X	X	_____	X	X	X	_____
8F	_____	X	X	X	_____	X	X	_____
1R	X	X	_____	X	X	_____	_____	X
2R	X	X	_____	_____	X	X	_____	X
3R	X	X	_____	X	_____	X	_____	X
4R	X	X	_____	X	X	_____	X	_____
5R	X	X	_____	_____	X	X	X	_____
6R	X	X	_____	X	_____	X	X	_____

Lube Bypass Check

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Table 18
Lube Bypass Check		Input Speed (2100 rpm max)Neutral position
Lube Bypass Pressure	517 ± 34 kPa (75 ± 5 psi)	kPa (psi)
		rpm

Cooler Bypass Check

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Table 19
Cooler Bypass Check		Input Speed (2100 rpm) NEUTRAL position Cooler Bypass Pressure 517 ± 34 kPa (75 ± 5 psi)
Cooler Bypass Pressure	517 ± 34 kPa (75 ± 5 psi)	kPa (psi)

Contamination Control

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Table 20
Contamination Control	Sample the test bench oil supply. *ISO 4406 is 16/13 or better	________/________Particle Count

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Table 21
______________________________________ Technician	______________________________________ Supervisor

Information System:

120K Motor Grader Capacities (Refill)

938H Wheel Loader and IT38H Integrated Toolcarrier Hydraulic System Relief Valve (Line)

120K Motor Grader Tire Shipping Pressure

2007/07/23 Troubleshooting the Rotary Switch Assembly for the Engine Speed {1408, 7332}

2008/02/11 An Improved Exhaust Piping Is Now Used on Track Skidders {1061, 1062}

120K Motor Grader Lifting and Tying Down the Machine

2007/11/19 Improvement to the Governor Control Groups {1265, 1276}

3408E and 3412E Engines for the 844 Wheel Dozer and for 988F Series II and 990 Series II Wheel Loaders Ether Starting Aid - Test

120K Motor Grader Specifications

CS-563E, CP-563E, CS-573E, CP-573E, CS-583E, CP-583E, CS-663E, CP-663E and CS-683E Vibratory Soil Compactors Additional Messages

R1600G Load Haul Dump 3176C Engine Supplement System Pressure - Release

R1600G Load Haul Dump Hydraulic System System Pressure - Release

587R Pipelayer Machine Systems Pilot Control Valve - Remove - Load, Boom, and Counterweight

587R Pipelayer Machine Systems Pilot Control Valve - Install - Load, Boom and Counterweight

938H Wheel Loader and IT38H Integrated Toolcarrier Hydraulic System Ride Control Valve (2-Function, 3-Function Control Valve)

R1600G Load Haul Dump Power Train Torque Converter and Updrive

R1600G Load Haul Dump Machine Electrical System Circuit Breaker

R1600G Load Haul Dump Steering System Articulated Hitch

R1600G Load Haul Dump Power Train Output Transfer Gears - Adjust

C4.4 and C6.6 Engines for Caterpillar Built Machines Event Codes

C4.4 and C6.6 Engines for Caterpillar Built Machines E360 Low Engine Oil Pressure

C18 Engine for Caterpillar Built Machines Component Location

R1600G Load Haul Dump Power Train Differential Pinion Preload - Adjust

R1600G Load Haul Dump Power Train Differential Backlash and Bearings - Adjust




Illustration 50	g03736642
0 - 4000 kPa (0 - 580 psi) (18) Parking Break Pressure




Illustration 51	g03736646
0 - 965 kPa (0 - 140 psi) (19) Flywheel Lube Pressure




Illustration 52	g03736673
0 - 4000 kPa (0 - 580 psi) (20) Differential Lock Pressure




Illustration 53	g03736688
0 - 965 kPa (0 - 140 psi) (21) Lube Relief Pressure




Illustration 54	g03737630
0 - 4000 kPa (0 - 580 psi) (22) Main Relief Pressure




Illustration 55	g03737644
0 - 965 kPa (0 - 140 psi) (23) Input Shaft Lube Pressure




Illustration 56	g03737652
0 - 965 kPa (0 - 140 psi) (24) Shaft 3 Lube Pressure




Illustration 57	g03737668
0 - 965 kPa (0 - 140 psi) (25) Shaft 2 Lube Pressure




Illustration 58	g03737688
0 - 965 kPa (0 - 140 psi) (26) Shaft 4 Lube Pressure




Illustration 59	g03737696
0 - 965 kPa (0 - 140 psi) (27) Output Shaft Lube Pressure




Illustration 9	g01395573




Illustration 10	g03735423




Illustration 11	g03735427




Illustration 12	g03735456




Illustration 60	g03738600
0 - 4000 kPa (0 - 580 psi) (28) Pump Pressure

Start Checks	Input Speed (800 rpm)
Pump Flow	49 ± 6 L/min (13 ± 1.5 US gpm)
Main Relief Pressure	2482 ± 69 kPa (360 ± 10 psi)