Bench Test Procedure for a TH336C, TH337C, TH406C, TH407C, TH357D, TH408D, TH3510D, and TPG145 Telehandler 6 Speed Transmission {3030} Caterpillar

OEM

OEMTPG145 (S/N: DY31-UP)

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: TD61-UP; TD71-UP)

TH406C (S/N: RCH1-UP; GAT1-UP)

TH407C (S/N: MLH1-UP; JJT1-UP)

TH408D (S/N: TH41-UP; TH91-UP)

Introduction

© 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.

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.

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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.

Installation Procedure

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Illustration 3	g06148494

1. Install Tooling (A) to the test stand.
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   Illustration 4	g06148503

2. Install Tooling (B) to the left and right sides of transmission.
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3. Use the hoist to install the transmission onto Tooling (A). The weight of the transmission is 385 kg (850 lb).
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4. If a flex plate is present, remove and install Tooling (C).
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5. Install Tooling (D) to Tooling (C).
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   Illustration 8	g06148523

6. Use a hoist to install Tooling (E) to the transmission.
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   Illustration 9	g06156899

7. Install Tooling (F) to support the transmission. Shim between Tooling (A) and Tooling (F) using 1 washer.
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   Illustration 10	g06156907

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8. 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.

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   Illustration 12	g06156938

9. Install Tooling (H).
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   Illustration 13	g06156957

10. Install Tooling (J) onto Tooling (E).
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    Illustration 14	g06156960

11. Install Tooling (K) onto Tooling (J).
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    Illustration 15	g06156966

12. Install Tooling (L) onto Tooling (K).
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    Illustration 16	g06156975

13. Use a hoist to align the transmission with the input drive shaft.

14. Connect the input drive shaft to Tooling (L).
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    Illustration 17	g06156978

15. Close and latch drive shaft guard.
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    Illustration 18	g06156985

16. Tighten all four castle nuts and jack bolts.

17. Re-tighten Tooling (G).
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    Illustration 19	g06215696

18. Install Tooling (N).
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19. Install Tooling (N).
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20. Install Tooling (N).
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21. Install Tooling (N).
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22. Install Tooling (N).
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23. Install Tooling (P).
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    Illustration 25	g06215667

24. Remove Oil Filter.
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    Illustration 26	g06215678

25. Install Tooling (U).
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    Illustration 27	g06215712
    (1) Transmission Pump (out) (2) Pump Flow (in)

26. Connect Hose Assembly (1) from Tooling (U) to Flowmeter 1 (in).

27. Connect Hose Assembly (2) from Flowmeter 1 (out) to Tooling (U).
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    Illustration 28	g06215724
    Torque Converter (out)

28. Connect Hose Assembly (3) from Tooling (P) to Flowmeter 2 (in).

29. Not pictured: Connect Hose Assembly (4) from Flowmeter 2 (out) to Heat Exchanger (in) port on test bench.
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    Illustration 29	g06215728
    Lube (in)

30. Connect Hose Assembly (5) from Heat Exchanger (out) port on test bench to Tooling (P).
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    Illustration 30	g06215730
    Spindle Lube

31. Connect Hose Assembly (6) to Tooling (J).
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    Illustration 31	g06215734
    (7) Forward High Pressure (8) Clutch 3 Pressure

32. Connect Pressure Gauges (7) and (8) to Tooling (N).
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    Illustration 32	g06215741
    Reverse Clutch Pressure

33. Connect Pressure Gauge (9) to Tooling (N).
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    Illustration 33	g06215743
    Forward Low Clutch Pressure

34. Connect Pressure Gauge (10) to Tooling (N).
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    Illustration 34	g06215744
    Lube Pressure

35. Connect Pressure Gauge (11) to Tooling (N).
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    Illustration 35	g06215756
    Pump Pressure

36. Connect Pressure Gauge (12) to Tooling (N).
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    Illustration 36	g06215796
    Torque Converter (in) Pressure

37. Connect Pressure Gauge (13) to Tooling (N).
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    Illustration 37	g06215807
    (14) Clutch 1 Pressure (15) Clutch 2 Pressure

38. Connect Pressure Gauges (14) and (15) to Tooling (N).
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    Illustration 38	g06215809
    (16) Solenoid 4 (4-D) (17) Solenoid 5 (5-E)

39. Install Tooling (R) to Solenoids (16) and (17).
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    Illustration 39	g06215812
    (18) Solenoid 6 (6-F) (19) Solenoid 3 (3-C)

40. Install Tooling (R) to Solenoids (18) and (19).
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    Illustration 40	g06215814
    (20) Solenoid 1 (1-A) (21) Solenoid 2 (2-B)

41. Install Tooling (R) to Solenoids (20) and (21).
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    Illustration 41	g06157236

42. Install Tooling (R) to Tooling (S).
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    Illustration 42	g06157244

43. Connect Tooling (S) to Tooling (T). Refer to Tool Operating Manual , NEHS0966 for the correct operating instructions.

Test Procedure

TA3 Navigation

1. Select "Telehandler".

2. Select ""C" 6 Speed", or""D" 6 Speed".

Harness Test

1. Make sure Tooling (R) and (S) are properly connected.

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

3. Record values in Table 6.

   Note: Do not continue testing until Harness Test passes.

Start Check

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Illustration 43	g06157253

1. Use the dipstick to ensure that proper oil level is reached.

2. 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 during the test.
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   Illustration 44	g02720621

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1200 ± 20 rpm.

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

5. 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.

6. Confirm correct clutch engagement with Table 4.
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   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
   F5			X		X
   F6			X	X
   R1	X					X
   R2		X				X
   R3			X			X

7. Stop input rotation.

Low Idle Test

1. With the transmission in neutral, adjust input rotation to 1200 ± 20 rpm.

2. Record Pump Flow, Lube, Pump, Torque Converter Pressures, and Horse Power Loss in Table 8.

3. Confirm values with Table 7.

4. Record Clutch Pressures in Table 10.

5. Confirm values with Table 9.

   Note: If the values do not meet criteria, stop the test and verify test stand hook ups, calibrations, and/or repair/adjust the transmission.

6. Shift to Forward 1, Forward 2, Forward 3, Forward 4, Forward 5, Forward 6, Reverse 1, Reverse 2, and Reverse 3.

   Note: Always shift the transmission back to neutral when shifting between forward and reverse.

7. Repeat Steps 2 through 5 with each gear range.

High Idle Test

1. With the transmission in neutral, adjust input rotation to 1200 ± 20 rpm.

2. Adjust the input rotation to 1600 ± 20 rpm.

3. Record Pump Flow, Lube, Pump, Torque Converter Pressures, and Horse Power Loss in Table 12.

4. Confirm values with Table 11.

5. Record Clutch Pressures in Table 14.

6. Confirm values with Table 13.

7. Adjust the input rotation to 1200 ± 20 rpm.

8. Shift to Forward 1, Forward 2, Forward 3, Forward 4, Forward 5, Forward 6, Reverse 1, Reverse 2, and Reverse 3.

9. 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

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 15.

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

Transmission Bench Test Data Sheet

Harness Test

Low Idle Test

High Idle Test

Contamination Control