- Telehandler
- TH336C (S/N: THM1-UP; MJR1-UP)
- TH337C (S/N: DJB1-UP; SXJ1-UP)
- TH3510D (S/N: TH21-UP; TH31-UP)
- TH357D (S/N: TD71-UP)
- TH406C (S/N: RCH1-UP; GAT1-UP)
- TH407C (S/N: MLH1-UP; JJT1-UP)
- TH408D (S/N: TH91-UP)
- TH414C (S/N: KEK1-UP; RWW1-UP)
- TH417C (S/N: RRJ1-UP; RRW1-UP)
- TH514C (S/N: MWC1-UP; KKW1-UP)
- TH514D (S/N: MWG1-UP)
- TL1055C (S/N: MDD1-UP; KDE1-UP)
- TL1055D (S/N: ML51-UP; MNT1-UP)
- TL1255C (S/N: SXM1-UP; DHW1-UP)
- TL1255D (S/N: ML71-UP; MYW1-UP)
- TL642C (S/N: THG1-UP; THL1-UP)
- TL642D (S/N: ML81-UP; MLG1-UP)
- TL943C (S/N: SXH1-UP; THH1-UP)
- TL943D (S/N: MLD1-UP; MLJ1-UP)
- TH337C (S/N: DJB1-UP; SXJ1-UP)
Introduction
Revision | Summary of Changes in M0078020 |
03 | Title Change. |
02 | Title change and update to Table 2.
Add serial number prefixes Update to Table 3. |
01 | Title change and update to Table 2. |
00 | New Document |
© 2017 Caterpillar All Rights Reserved. This guideline 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 Caterpillar: Confidential Yellow.
This special instruction 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 guideline 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 guideline 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.
Machine Model | Transmission Arrangement |
TH414C | |
TH417C | |
TH514C | |
TL642C | |
TL943C | |
TL1055C | |
TL1255C | |
TH336C | |
TH337C | |
TH406C | |
TH407C | |
TH357D | |
TH408D | |
TH514D | |
TH3510D | |
TL642D | |
TL943D | |
TL1055D | |
TL1255D |
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 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.
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 extra 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 | |
Adapter Ring | 1 | ||
Rail As | 2 | ||
Bracket As | 2 | ||
Mounting Block Gp | 1 | ||
B | Support Plate | 1 | |
Support Plate | 1 | ||
Bolt | 8 | ||
Hard Washer | 8 | ||
C | Adapter | 1 | |
Bolt | 6 | ||
D | Drive Adapter Gp | 1 | |
Bolt (1/2-13X1.5-IN) | 8 | ||
Hard Washer | 8 | ||
E | Adapter As | 1 | |
Bolt (3/8-16X1.25-IN) | 6 | ||
Lockwasher | 6 | ||
F | Corssmember | 1 | |
Bolt | 4 | ||
Hard Washer | 8 | ||
Full Nut | 4 | ||
G | Load Binder As | 4 | |
Lifting Eye Assembly | 4 | ||
H | Support Plate Gp | 1 | |
Bolt | 4 | ||
Washer | 4 | ||
J | Spindle Gp | 1 | |
Bolt (1/2-13X1.75 inch) | 4 | ||
Lockwasher | 4 | ||
K | Adapter As (DRIVE) | 1 | |
L | Drive Adapter (KEY)(4) | 1 | |
M | Drive Adapter(5) | 1 | |
N | Fitting | 10 | |
P | O-Ring Adapter | 2 | |
Adapter | 2 | ||
Adapter | 2 | ||
Fitting As | 2 | ||
Q(6) | Ball Valve | 2 | |
Adapter | 2 | ||
Quick Coupler | 2 | ||
Fitting As | 2 | ||
R | Test Cable As | 1 | |
Cable Adapter | 6 | ||
S | Extension Cable | 1 | |
T | Transmission Analyzer Gp | 1 | |
U | Housing Adapter (TRANSMISSION OIL FILTER) | 1 | |
O-Ring Seal | 1 | ||
Elbow | 1 | ||
Reducer Bushing | 2 | ||
Pipe Nipple | 2 | ||
Fitting As | 2 | ||
V(7) | Portable Hydraulic Tester | 1 | |
W(7) | Pressure Gauge (0 TO 4,000-KPA (0 TO 580-PSI)) | 9 | |
Quick Connect Coupler | 9 | ||
X(7) | Pressure Gauge (0 TO 1,000-KPA (0 TO 144-PSI)) | 1 | |
Quick Connect Coupler | 1 |
(1) | Ring will need to be modified to |
(2) | For use if test bed platform is flush with the floor |
(3) | Plate will need to be modified to |
(4) | For use with the small drive shaft. |
(5) | For use with the large drive shaft. |
(6) | Optional Tooling to use to prevent transmission backfill when test is stopped. |
(7) | Optional Tooling if needed with Test Bench. |
Installation Procedure
- Install Tooling (A) to the test stand.
Show/hide table
Illustration 4 g06148503 - Install Tooling (B) to the left and right sides of transmission.
Show/hide table
Illustration 5 g06148510 - Use the hoist to install the transmission onto Tooling (A). The weight of the transmission is
385 kg (850 lb) .Show/hide tableIllustration 6 g06148516 - If a flex plate is present, remove and install Tooling (C).
Show/hide table
Illustration 7 g06148520 - Install Tooling (D) to Tooling (C).
Show/hide table
Illustration 8 g06148523 - Use a hoist to install Tooling (E) to the transmission.
Show/hide table
Illustration 9 g06156899 - Install Tooling (F) to support the transmission. Shim between Tooling (A) and Tooling (F) using 1 washer.
Show/hide table
Illustration 10 g06156907 Show/hide tableIllustration 11 g06156910 - Install Tooling (G) on both sides of the transmission to prevent movement during testing.
Note: Over-tightening Tooling (G) can jeopardize the tightening ability of the castle nuts on Tooling (A) later in this section.
Show/hide tableIllustration 12 g06156938 - Install Tooling (H).
Show/hide table
Illustration 13 g06156957 - Install Tooling (J) onto Tooling (E).
Show/hide table
Illustration 14 g06156960 - Install Tooling (K) onto Tooling (J).
Show/hide table
Illustration 15 g06156966 - Install Tooling (L) onto Tooling (K).
Show/hide table
Illustration 16 g06156975 - Use a hoist to align the transmission with the input drive shaft.
- Connect the input drive shaft to Tooling (L).
Show/hide table
Illustration 17 g06156978 - Close and latch drive shaft guard.
Show/hide table
Illustration 18 g06156985 - Tighten all four castle nuts and jack bolts.
- Re-tighten Tooling (G).
Show/hide table
Illustration 19 g06215696 - Install Tooling (N).
Show/hide table
Illustration 20 g06157005 - Install Tooling (N).
Show/hide table
Illustration 21 g06157006 - Install Tooling (N).
Show/hide table
Illustration 22 g06215654 - Install Tooling (N).
Show/hide table
Illustration 23 g06157014 - Install Tooling (N).
Show/hide table
Illustration 24 g06157017 - Install Tooling (P).
Show/hide table
Illustration 25 g06215667 - Remove Oil Filter.
Show/hide table
Illustration 26 g06215678 - Install Tooling (U).
Show/hide table
Illustration 27 g06215712 (1) Transmission Pump (out)
(2) Pump Flow (in) - Connect Hose Assembly (1) from Tooling (U) to Flowmeter 1 (in).
- Connect Hose Assembly (2) from Flowmeter 1 (out) to Tooling (U).
Show/hide table
Illustration 28 g06215724 Torque Converter (out) - Connect Hose Assembly (3) from Tooling (P) to Flowmeter 2 (in).
- Not pictured: Connect Hose Assembly (4) from Flowmeter 2 (out) to Heat Exchanger (in) port on test bench.
Show/hide table
Illustration 29 g06215728 Lube (in) - Connect Hose Assembly (5) from Heat Exchanger (out) port on test bench to Tooling (P).
Show/hide table
Illustration 30 g06215730 Spindle Lube - Connect Hose Assembly (6) to Tooling (J).
Show/hide table
Illustration 31 g06215734 (7) Forward High Pressure
(8) Clutch 3 Pressure - Connect Pressure Gauges (7) and (8) to Tooling (N).
Show/hide table
Illustration 32 g06215741 Reverse Clutch Pressure - Connect Pressure Gauge (9) to Tooling (N).
Show/hide table
Illustration 33 g06215743 Forward Low Clutch Pressure - Connect Pressure Gauge (10) to Tooling (N).
Show/hide table
Illustration 34 g06215744 Lube Pressure - Connect Pressure Gauge (11) to Tooling (N).
Show/hide table
Illustration 35 g06215756 Pump Pressure - Connect Pressure Gauge (12) to Tooling (N).
Show/hide table
Illustration 36 g06215796 Torque Converter (in) Pressure - Connect Pressure Gauge (13) to Tooling (N).
Show/hide table
Illustration 37 g06215807 (14) Clutch 1 Pressure
(15) Clutch 2 Pressure - Connect Pressure Gauges (14) and (15) to Tooling (N).
Show/hide table
Illustration 38 g06215809 (16) Solenoid 4 (4-D)
(17) Solenoid 5 (5-E) - Install Tooling (R) to Solenoids (16) and (17).
Show/hide table
Illustration 39 g06215812 (18) Solenoid 6 (6-F)
(19) Solenoid 3 (3-C) - Install Tooling (R) to Solenoids (18) and (19).
Show/hide table
Illustration 40 g06215814 (20) Solenoid 1 (1-A)
(21) Solenoid 2 (2-B) - Install Tooling (R) to Solenoids (20) and (21).
Show/hide table
Illustration 41 g06157236 - Install Tooling (R) to Tooling (S).
Show/hide table
Illustration 42 g06157244 - Connect Tooling (S) to Tooling (T). Refer to Tool Operating Manual , NEHS0966 for the correct operating instructions.
Illustration 3 | g06148494 |
TA3 Navigation
- Select "Telehandler".
- Select "C 4 Speed" or "D 4 Speed".
Harness Test
- Make sure Tooling (R) and (S) are properly connected.
- Use Tooling (T) to perform the harness test.
- Record values in Table 6.
Note: Do not continue testing until Harness Test passes.
Start Check
- Use the dipstick to ensure that proper oil level is reached.
- 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 during the test.Show/hide tableIllustration 44 g02720621 - With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1200 ± 20 rpm.
- Shift the transmission through all gears to eliminate air from the transmission controls.
- Lube pressure should be minimum
21 kPa (3 psi) .Note: If there is no lube pressure after 30 seconds, stop the test and verify test stand and transmission connections.
- Confirm correct clutch engagement with Table 4.
Show/hide table
Table 4 Clutch Engagement Check Gear CL 1 CL 2 CL 3 FH CL FL CL R CL F1 X X F2 X X F3 X X F4 X X R1 X X R2 X X R3 X X - Stop input rotation.
Illustration 43 | g06157253 |
Low Idle Test
- With the transmission in neutral, adjust input rotation to 1200 ± 20 rpm.
- Record Pump Flow, Lube, Pump, Torque Converter Pressures, and Horse Power Loss in Table 8.
- Confirm values with Table 7.
- Record Clutch Pressures in Table 10.
- Confirm values with Table 9.
- Repeat Steps 2 through 5 with each gear range.
Note: Always shift the transmission back to neutral when shifting between forward and reverse.
High Idle Test
- With the transmission in neutral, adjust input rotation to 1200 ± 20 rpm.
- Adjust the input rotation to 1600 ± 20 rpm.
- Record Pump Flow, Lube, Pump, Torque Converter Pressures, and Horse Power Loss in Table 12.
- Confirm values with Table 11.
- Record Clutch Pressures in Table 14.
- Confirm values with Table 13.
- Adjust the input rotation to 1200 ± 20 rpm.
- Repeat Steps 2 through 7 with each gear range.
Note: Always shift the transmission back to neutral when shifting between forward and reverse.
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 15.
- 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.:_______ |
Harness Test
Harness Test | Solenoid 1 | Solenoid 2 | Solenoid 3 | Solenoid 4 | Solenoid 5 | Solenoid 6 |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
Low Idle Test
Low Idle Test
1200 ± 20 rpm |
||||||||
Gear | Pump Flow | Lube Flow | Leakage Flow | Pump Pressure | Inlet Pressure | TC Pressure | Lube Pressure | Hp Loss |
N | |
|
Max |
|
|
|
|
|
F1 | |
|
Max |
|
|
|
|
|
F2 | |
|
Max |
|
|
|
|
|
F3 | |
|
Max |
|
|
|
|
|
F4 | |
|
Max |
|
|
|
|
|
R1 | |
|
Max |
|
|
|
|
|
R2 | |
|
Max |
|
|
|
|
|
R3 | |
|
Max |
|
|
|
|
|
Low Idle Test
1200 ± 20 rpm |
||||||||
Gear | Pump Flow | Lube Flow | Leakage Flow | Pump Pressure | Inlet Pressure | TC Pressure | Lube Pressure | Hp Loss |
N | ___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
F1 | ___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
F2 | ___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
F3 | ___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
F4 | ___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
R1 | ___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
R2 | ___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
R3 | ___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
Low Idle Clutch Pressures
1200 ± 20 rpm |
||||||
Gear | CL 1 | CL 2 | CL 3 | Forward High Clutch | Forward Low Clutch | Reverse Clutch |
F1 | |
|
||||
F2 | |
|
||||
F3 | |
|
||||
F4 | |
|
||||
R1 | |
|
||||
R2 | |
|
||||
R3 | |
|
Low Idle Clutch Pressures
1200 ± 20 rpm |
||||||
Gear | CL 1 | CL 2 | CL 3 | Forward High Clutch | Forward Low Clutch | Reverse Clutch |
F1 | ___________ |
___________ |
||||
F2 | ___________ |
___________ |
||||
F3 | ___________ |
___________ |
||||
F4 | ___________ |
___________ |
||||
R1 | ___________ |
___________ |
||||
R2 | ___________ |
___________ |
||||
R3 | ___________ |
___________ |
High Idle Test
High Idle Test
1600 ± 20 rpm |
||||||||
Gear | Pump Flow | Lube Flow | Leakage Flow | Pump Pressure | Inlet Pressure | TC Pressure | Lube Pressure | Hp Loss |
N | |
|
Max |
|
|
|
|
|
F1 | |
|
Max |
|
|
|
|
|
F2 | |
|
Max |
|
|
|
|
|
F3 | |
|
Max |
|
|
|
|
|
F4 | |
|
Max |
|
|
|
|
|
R1 | |
|
Max |
|
|
|
|
|
R2 | |
|
Max |
|
|
|
|
|
R3 | |
|
Max |
|
|
|
|
|
High Idle Test
1600 ± 20 rpm |
||||||||
Gear | Pump Flow | Lube Flow | Leakage Flow | Pump Pressure | Inlet Pressure | TC Pressure | Lube Pressure | Hp Loss |
N | ___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
F1 | ___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
F2 | ___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
F3 | ___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
F4 | ___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
R1 | ___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
R2 | ___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
R3 | ___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
___________ |
High Idle Clutch Pressures
1600 ± 20 rpm |
||||||
Gear | CL 1 | CL 2 | CL 3 | Forward High Clutch | Forward Low Clutch | Reverse Clutch |
F1 | |
|
||||
F2 | |
|
||||
F3 | |
|
||||
F4 | |
|
||||
R1 | |
|
||||
R2 | |
|
||||
R3 | |
|
High Idle Clutch Pressures
1600 ± 20 rpm |
||||||
Gear | CL 1 | CL 2 | CL 3 | Forward High Clutch | Forward Low Clutch | Reverse Clutch |
F1 | ___________ |
___________ |
||||
F2 | ___________ |
___________ |
||||
F3 | ___________ |
___________ |
||||
F4 | ___________ |
___________ |
||||
R1 | ___________ |
___________ |
||||
R2 | ___________ |
___________ |
||||
R3 | ___________ |
___________ |
Contamination Control
ISO Particle Count | Sample the test bench oil supply. *ISO 4406 is 16/13 or better |
________/________Particle Count |
______________________________________ Technician |
______________________________________ Supervisor |