120H Motor Grader 6TM00001-00442 (MACHINE) POWERED BY 3116 Engine(S...

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Product: MOTOR GRADER

Model: 120H MOTOR GRADER 6TM
Configuration: 120H Motor Grader 6TM00001-00442 (MACHINE) POWERED BY 3116 Engine

Testing and Adjusting

120H, 12H, 135H, 140H, 143H, 160H and 163H Motor Graders Power Train
Media Number -SENR8503-03 Publication Date -01/12/2005 Date Updated -15/12/2005

i02424221

Transmission Pressures - Test

SMCS - 3030-081-PX; 3073-081-PX; 3074-081-PX

When testing and adjusting the transmission and power train, move the
machine to an area clear of obstructions, with safe exhaust ventilation
for the exhausts. Sudden movement of the machine or release of oil
under pressure can cause injury to persons on or near the machine. To
prevent possible injury, do the procedure that follows before testing and
adjusting the transmission and power train.

Personal injury can result from spring force released when removing
cap screws.

Internal spring force will be released when cylinder assembly cap

screws are removed causing injury.

Always restrain cover as cap screws are loosened.

Follow the established procedure in the Service Manual to service these

parts.

NOTICE

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Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting, and repair
of the machine. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Dispose of all fluids according to local regulations and mandates.

Before you begin the test, refer to Troubleshooting, "Machine Preparation for Troubleshooting".

Table 1
Required Tools
Part Number Description Quantity
1U-5482 Pressure Adapter Group 1
1U-5481 Pressure Gauge Group 1
8T-0856 Pressure Gauge (0 to 6,000 kPa (0 to 870 psi)) 3

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Illustration 1 g01211276

(A) Test port for clutch pack 3

(B) Test port for clutch pack 1

(C) Test port for clutch pack 2

(D) Test port for clutch pack 8

(E) Test port for clutch pack 4

(F) Test port for clutch pack 6

(G) Test port for clutch pack 5

(H) Test port for clutch pack 7

Table 2
Transmission Clutch Pressure with Differential Lock OFF

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Station NEUTRAL FIRST GEAR SECOND GEAR FIRST

Position at FORWARD FORWARD REVERSE
LOW Idle Position at LOW Position at LOW GEAR Position at
Idle Idle LOW Idle
(A)
0.0 kPa (.00 psi) 0.0 kPa (.00 psi) 0.0 kPa (.00 psi) 2255 ± 110 kPa
(327 ± 16 psi)
(B)
0.0 kPa (.00 psi) 2180 ± 95 kPa (316 0.0 kPa (.00 psi) 0.0 kPa (.00 psi)
± 14 psi)
(C)
0.0 kPa (.00 psi) 0.0 kPa (.00 psi) 2350 ± 95 kPa (341 0.0 kPa (.00 psi)
± 14 psi)
(D)
2670 ± 95 kPa 0.0 kPa (.00 psi) 0.0 kPa (.00 psi) 0.0 kPa (.00 psi)
(387 ± 14 psi)
(E)
0.0 kPa (.00 psi) 0.0 kPa (.00 psi) 1965 ± 110 kPa (285 0.0 kPa (.00 psi)
± 16 psi)
(F)
0.0 kPa (.00 psi) 2670 ± 90 kPa (387 0.0 kPa (.00 psi) 2670 ± 90 kPa
± 13 psi) (390 ± 13 psi)
(G)
2790 ± 85 kPa 0.0 kPa (.00 psi) 0.0 kPa (.00 psi) 0.0 kPa (.00 psi)
(405 ± 12 psi)
(H)
0.0 kPa (.00 psi) 1540 ± 85 kPa (223 1540 ± 85 kPa (223 1540 ± 85 kPa
± 12 psi) ± 12 psi) (223 ± 12 psi)
Transmission Lubrication Pressure with Differential Lock OFF
NEUTRAL FIRST GEAR SECOND GEAR FIRST
Position FORWARD FORWARD REVERSE
Position Position GEAR Position
LOW
Idle 80 ± 30 kPa (12 7 kPa (1 psi) 7 kPa (1 psi) 7 kPa (1 psi)
± 4 psi) minimum minimum minimum
HIGH
Idle 340 kPa (50 psi) 241 ± 27 kPa (35 ± 241 ± 27 kPa (35 ± 4 241 ± 27 kPa (35 ±
4 psi) psi) 4 psi)
Transmission Lubrication Pressure with Differential Lock ON
NEUTRAL FIRST GEAR SECOND GEAR FIRST
Position FORWARD FORWARD REVERSE
Position Position GEAR Position

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LOW
Idle 80 ± 30 kPa (12 7 kPa (1 psi) 7 kPa (1 psi) 7 kPa (1 psi)
± 4 psi) minimum minimum minimum
HIGH
Idle 340 kPa (50 psi) 241 ± 27 kPa (35 ± 241 ± 27 kPa (35 ± 4 241 ± 27 kPa (35 ±
4 psi) psi) 4 psi)

Table 3
Transmission Clutch Pressure with Differential Lock OFF
Station NEUTRAL FIRST GEAR SECOND GEAR FIRST GEAR
Position at FORWARD FORWARD REVERSE
LOW Idle Position at LOW Position at LOW Position at LOW
Idle Idle Idle
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
Transmission Lubrication Pressure with Differential Lock OFF
NEUTRAL FIRST GEAR SECOND GEAR FIRST
Position FORWARD FORWARD REVERSE
Position Position GEAR Position
LOW
Idle
HIGH
Idle
Transmission Lubrication Pressure with Differential Lock ON
NEUTRAL FIRST GEAR SECOND GEAR FIRST
Position FORWARD FORWARD REVERSE
Position Position GEAR Position
LOW
Idle
HIGH
Idle

1. Operate the machine until the transmission oil is at operating temperature of 51 °C (124 °F).

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2. Stop the machine on a hard level surface. Move the transmission control lever to the
NEUTRAL position. Turn the engine OFF. Place blocks in front of the wheels and place
blocks behind the wheels.

Illustration 2 g01211301

(1) Transmission

(2) Cover for the transmission control valve

3. Remove cover (2) from transmission (1). Remove the differential drive shaft.

4. Attach the 8T-0856 Pressure Gauges (0 to 6,000 kPa (0 to 870 psi)) to test ports (D) and
(G). Operate the engine at high idle with the transmission control (lever) in the NEUTRAL
position. Record the pressure readings in Table 3. Remove the gauges.

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5. Attach the 8T-0856 Pressure Gauges (0 to 6,000 kPa (0 to 870 psi)) to test port (B), (D), and
(F). Operate the engine at high idle with the transmission control (lever) in FIRST GEAR
FORWARD. Record the pressure readings in Table 3. Remove the gauges.

6. Attach the 8T-0856 Pressure Gauges (0 to 6,000 kPa (0 to 870 psi)) to test ports (C), (E),
and (H). Operate the engine at high idle with the transmission control (lever) in SECOND
GEAR FORWARD. Record the pressure readings in Table 3. Remove the gauges.

7. Attach the 8T-0856 Pressure Gauges (0 to 6,000 kPa (0 to 870 psi)) to test ports (A), (F),
and (H). Operate the engine at high idle with the transmission control (lever) in FIRST
GEAR REVERSE. Record the pressure readings in table 3. Remove the gauges. If the
pressures need to be adjusted, refer to Systems Operation, Testing and Adjusting, "Initial
Pressures - Test and Adjust".

8. Install the guards and the differential drive shaft.

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