Bench Test Procedure for TH48FT - E80 Oil Field Transmission{3030, 3073, 3101} Caterpillar

Petroleum Transmission:

TH48-E80 (S/N: FRT1-UP)

Introduction

Table 1

Summary of Changes in REHS2828-03

Added transmission arrangements and new introduction.

© 2011 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.

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 in order 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 questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. In order to address an urgent need, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

• Cat Dealer Techinical Communicator

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• Knowledge Network

Table 2

Machine Model	Transmission Arrangement
TH48FT - E80	258-8740, 290-3262, 315-0053, 315-0054, 353-6003, 341-1845

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.

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 in order 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 additional filtering can affect pressure. The required tools that are listed in Table 3 were used in order to develop this test procedure.

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	189-0409	Shackle	1
	138-7574	Link Bracket	2
	9X-8886	Bolt (3/4-10 x 2.75 inch)	2
	2J-3506	Full Nut	2
	5P-8248	Hard Washer	2
B	1U-9584	Rail As	2
	1U-9585	Block Gp (Transmission Mounting)	1
C	1U-9722	Load Binder As (Ratchet Type)	3
D	9F-2247	Pipe Plug	2
E	3P-9497	Pipe Plug	1
F	3D-4603	Pipe Plug	1
G	271-3644	Drive Adapter	1
	0S-1595	Bolt (1/2-13 x 1.25 inch)	12
	5P-8245	Hard Washer	12
H	1U-5119	Adapter Ring	1
	8B-7997	Hex Socket Head Screw Bolt (1/2-13 x 2.00 inch)	4
	5P-8245	Hard Washer	4
J	283-5010	Adapter Plate	1
	1A-1460	Bolt (1/2-13 x 2.00 inch)	4
	5P-8245	Hard Washer	4
K	1U-5999	Spindle Gp	1
	8B-7997	Bolt (1/2-13X2.0 inch)	4
	3B-4508	Lockwasher	4
L	1U-6721	Adapter (Drive)	1
M	1U-9131	Drive Adapter (Key) (1)	1
N	1U-9359	Drive Adapter (2)	1
P	3B-6552	Elbow	1
	3B-7282	Pipe Nipple	1
	6V-4142	Fitting (Test)	1
Q	4C-4897	Cover (Transmission Test)	1
R	140-7300	90o Pipe Elbow	1
	9F-2535	90oPipe Street Elbow	2
	140-7299	Pipe Nipple	2
S	283-5006	Adapter	1
	1U-9879	Coupler	1
T	1U-8304	Fitting	2
	9U-7445	Adapter	2
	8C-9024	Fitting As (Plain)	2
	6V-3965	Fitting As (Quick Disconnect)	2
	1P-4578	Half Flange	4
	0T-0320	Bolt (7/16-14x1.25 inch)	8
	5P-8244	Hard Washer	8
	4J-0522	O-Ring Seal	2
	7M-8485	O-Ring Seal	2
U	1U-8301	Fitting	2
	9U-7446	Adapter	2
	1P-4579	Half Flange	4
	8C-9024	Fitting As (Plain)	2
	6V-3965	Fitting As (Quick Disconnect)	2
	0T-0772	Bolt (7/16-14x1.50 inch)	8
	5P-8244	Hard Washer	8
V	1U-8301	Fitting	1
	9U-7446	Adapter	1
	1P-4579	Half Flange	2
	8C-9024	Fitting As (Plain)	1
	6V-3965	Fitting As (Quick Disconnect)	1
	0V-0375	Bolt (1/2-13x3.25 inch)	4
	8T-4223	Hard Washer	4
W	1U-8301	Fitting	1
	9U-7446	Adapter	1
	1P-4579	Half Flange	2
	8C-9024	Fitting As (Plain)	1
	6V-3965	Fitting As (Quick Disconnect)	1
	0S-1585	Bolt (1/2-13x1.50 inch)	4
	8T-4223	Hard Washer	4
X	8C-9024	Fitting As (Plain)	1
	8C-9025	Quick Coupler	1
	3B-7749	Fitting	1
	120-6843	Ball Valve	1
Y		24 VDC Power Supply	1
		Wire	1
		Connectors	1
Z	9U-7500	Transmission Analyzer Tool Gp	1
	9U-7498	Adapter Cable As (Transmission Analyzer)	1
	1U-9482	Adapter Cable As	1
	4C-5974	Cable Adapter	2
AA	9U-7400	Multitach Tool Gp	1
	211-1774	Adapter Cable As (Speed Sensor)	1
BB	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	10
	6V-4144	Coupler	10
CC	8T-0863	Pressure Gauge (0 to 250 kPa (0 to 36 psi))	2
	6V-4144	Coupler	10

( 1 )	This drive adapter is used with the small drive shaft.
( 2 )	This drive adapter is used with the large drive shaft.

Tools Needed (Shift Traces)

Table 4

Required Tools
Tool	Part Number	Part Description	Qty
DD	131-5050	Dataview Tool Gp (1)	1
	148-9610	Computer Cart Gp	1
	4C-6818	Pressure Sensor (0 to 500 psi)	6
	6V-4144	Coupler	6
	131-5054	Adapter Cable As (Pressure Sensor)	6
	6V-2198	Cable	6

( 1 )

The compatible computer system is not included.

Installation Procedure

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Illustration 1	g01206189

1. Install Tooling (A) to the input end of the transmission.

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Illustration 2	g01206193

2. Install Tooling (A) to the output end of the transmission.

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Illustration 3	g01206196

3. Install Tooling (B) on the rails of the test bench, as shown.

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Illustration 4	g01206199

4. 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 5	g01206202

5. Install Tooling (C) to each side of the transmission input, as shown.

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Illustration 6	g01206206

6. Install Tooling (C) to the transmission output, as shown.

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Illustration 7	g01206207

7. Remove threaded drain plug (1) .

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Illustration 8	g01208710

8. Install Tooling (D) .

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Illustration 9	g01211009

9. Install Tooling (E) .

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Illustration 10	g01211010

10. Install Tooling (F) .

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Illustration 11	g01206210

11. Remove flywheel pilot (2) .

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Illustration 12	g01206211

12. Install Tooling (G) .

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Illustration 13	g01206213

13. Install Tooling (H) .

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Illustration 14	g01206214

14. Install Tooling (J) to Tooling (H) .

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Illustration 15	g01206216

15. Install Tooling (K) to Tooling (J) .

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Illustration 16	g01130792

16. Tighten the collet on Tooling (K) in order to connect Tooling (K) to Tooling (G) .

    Note: Refer to Special Instruction, SEHS8763, "Assembly and Operation of 1U-5999 Spindle Group Used for Testing Transmissions on Hydraulic Test Bench" for additional information.

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Illustration 17	g01206220

17. Install Tooling (L) to Tooling (K) .

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Illustration 18	g01206221

18. Install Tooling (M) to Tooling (L) .

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Illustration 19	g01206223

19. Align the transmission with the input drive shaft.

20. Connect the input drive shaft to Tooling (M) .

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Illustration 20	g01206224

21. Install the drive shaft guard and secure the drive shaft guard.

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Illustration 21	g01206227

22. Remove bracket (3) .

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Illustration 22	g01206232

23. Remove cover (4) .

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Illustration 23	g01206351

24. Remove threaded plug (5) .

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Illustration 24	g01206356

25. Install Tooling (P) .

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Illustration 25	g01206360

26. Install Tooling (Q) .

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Illustration 26	g01206373

27. Remove threaded plug (6) .

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Illustration 27	g01206377

28. Install Tooling (R) .

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Illustration 28	g01211018

29. Remove filter assembly (7) .

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Illustration 29	g01206384

30. Install Tooling (S) .

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Illustration 30	g01206400

31. Install Tooling (T) .

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Illustration 31	g01206402

32. Install Tooling (U) .

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Illustration 32	g01206404

33. Install Tooling (V) .

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Illustration 33	g01206405

34. Install Tooling (W) .

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Illustration 34	g01206408

35. Install Tooling (X) .

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Illustration 35	g01206424
(8) Suction Oil Supply

36. Install Hose Assembly (8) to Tooling (S) .

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Illustration 36	g01206426

37. Install Hose Assembly (9) from Tooling (T) to the inlet of the No. 2 flow meter.

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Illustration 37	g01206429
(10) Transmission Supply Oil

38. Install Hose Assembly (10) from the outlet of the No. 2 flow meter to Tooling (V) .

    Note: The No. 2 flow meter will measure the pump flow to the transmission controls.

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Illustration 38	g01206440
(11) Cooler Supply

39. Install Hose Assembly (11) from Tooling (U) to the inlet of the No. three flow meter.

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Illustration 39	g01206444
(12) Transmission Lubrication Oil

40. Install Hose Assembly (12) from the outlet of the No. three flow meter to Tooling (X) .

    Note: The No. 3 flow meter will measure the flow in the transmission oil cooler circuit.

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Illustration 40	g01206663

41. Install Hose Assembly (13) from Tooling (T) to the inlet of the No. four flow meter.

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Illustration 41	g01206664
(14) Torque Converter Inlet Oil

42. Install Hose Assembly (14) from the outlet of the No. four flow meter to Tooling (W) .

    Note: The No. 4 flow meter will measure the pump flow to the torque converter.

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Illustration 42	g01206666

43. Connect Hose Assembly (15) from the auxiliary oil supply at the test bench to Tooling (K). Maintain an oil pressure of 275 kPa (40 psi).

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Illustration 43	g01206670
(16) Transmission Lubrication Pressure

44. Connect a pressure gauge to test port (16) .

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Illustration 44	g01206672
(17) Transmission Supply Pressure

45. Connect a pressure gauge to test port (17) .

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Illustration 45	g01206673
(18) Priority Reduction Valve Pressure

46. Connect a pressure gauge to test port (18) .

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Illustration 46	g01206676
(19) Lockup Clutch Pressure

47. Connect a pressure gauge to test port (19) .

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Illustration 47	g01206678
(20) Torque Converter Inlet Pressure

48. Connect a pressure gauge to test port (20) .

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Illustration 48	g01206679
(21) Torque Converter Outlet Pressure

49. Connect a pressure gauge to test port (21) .

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Illustration 49	g01206680
(22) Speed Increaser Lubrication Pressure

50. Connect a pressure gauge to test port (22) .

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Illustration 50	g01461916
23 - Selector Valve Station A - Clutch 4 24 - Selector Valve Station B - Clutch 2 25 - Selector Valve Station C - Clutch 1 26 - Selector Valve Station E - Clutch 5 27 - Selector Valve Station G - Clutch 6 28 - Selector Valve Station H - Clutch 3

51. Connect a pressure gauge to each of the clutch pressure taps (23), (24), (25), (26), (27), and (28) .

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Illustration 51	g01206698

52. Install Tooling (Y) to the lockup clutch solenoid.

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Illustration 52	g00877510

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Illustration 53	g01206700

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Illustration 54	g01206701

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Illustration 55	g01206702
(29) Upshift Solenoid (30) Downshift Solenoid

53. Install Tooling (Z) .

54. Connect Tooling (Z) to a power source. Refer to Tool Operating Manual, NEHS0644 for the correct operating instructions.

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Illustration 56	g01211437

55. Install Tooling (AA) to the output speed sensor.

Test Procedure

Solenoid Test

1. Make sure that the harness is properly connected.

2. Use Tooling (Z) to perform the solenoid test.

3. Record the values in Table 9.

Preliminary Checks

Note: Refer to Testing and Adjusting, RENR9663, "TH48 - E80 Oil Field Transmission Power Train" for the correct adjusting procedures.

1. 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 57	g00877511

2. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 800 ± 30 rpm.

3. Shift the transmission through all speed ranges in order to eliminate air from the transmission controls.

4. Shift the transmission until all clutch fills are consistent.

5. The lubrication pressure must be 70 ± 12 kPa (10.2 ± 1.8 psi).

6. Stop the input rotation.

Priority Reducing Valve

1. Adjust the input rotation to 800 ± 30 rpm in the NEUTRAL position.

2. Shift the transmission to the FORWARD 1 position.

3. Check the pressure for the priority reducing valve. The correct pressure must be 1725 ± 70 kPa (250 ± 10 psi).

4. Record the value in Table 10.

Neutralizer Valve

1. Stop the input rotation in any range. Do not stop the input rotation in NEUTRAL or PARK.

2. Adjust the input rotation to 800 ± 30 rpm.

3. The neutralizer valve must prevent a pressure increase at any clutch station.

4. Record the values in Table 11.

5. Shift the transmission to the NEUTRAL or PARK position. The clutch pressure that is measured at pressure tap "C" must rise to a normal pressure in NEUTRAL. The clutch pressure that is measured at pressure taps "A" and "G" must rise to a normal pressure in PARK.

6. Record the value in Table 12.

Transmission Cooler Inlet Relief Valve

1. Adjust the input rotation to 850 ± 30 rpm.

2. Shift the transmission to FORWARD 1.

3. Adjust the input rotation in order to produce a cooler flow of 38.0 ± 0.4 L/min (10.0 ± .1 US gpm).

4. Use Tooling (X) in order to block the flow momentarily at the cooler outlet.

5. The inlet pressure for the transmission oil cooler must be 930 ± 138 kPa (135.0 ± 20.0 psi).

6. Record the value in Table 12.

Lube Check

1. Adjust the input rotation to 800 ± 30 rpm.

2. Shift the transmission to the FORWARD 1 position.

3. Record the lubrication pressure in Table 14. (Reference: 70.3 ± 12.4 kPa (10.2 ± 1.8 psi))

4. Record the lube flow in Table 14. (Reference: 98.4 ± 18.9 L/min (26.0 ± 5.0 US gpm))

5. Adjust the input rotation to 1950 ± 30 rpm.

6. Record the lubrication pressure in Table 15. (Reference: 367 ± 66 kPa (53.2 ± 9.5 psi))

7. Record the lube flow in Table 15. (Reference: 204 ± 19 L/min (54.0 ± 5.0 US gpm))

8. Shift the transmission through positions FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, FORWARD 7, and FORWARD 8. Repeat Steps 5 through 7 for each gear range.

Multifunction Manifold Pressures

1. Adjust the input rotation to 1950 ± 30 rpm.

2. Record the torque converter inlet pressure at pressure tap (20) in Table 16.

3. Record the torque converter outlet pressure at pressure tap (21) in Table 16.

4. Record the speed increaser lubrication pressure at pressure tap (22) in Table 16.

5. Adjust the input rotation to 0 rpm.

Table 5

Multifunction Manifold Pressures
Torque Converter Inlet Pressure	638 ± 293 kPa (92.5 ± 42.5 psi)
Torque Converter Outlet pressure	448 ± 138 kPa (65.0 ± 20.0 psi)
Speed Increaser Lubrication Pressure	276 ± 138 kPa (40.0 ± 20.0 psi)

Lockup Clutch Pressure

1. Adjust the input rotation to 1950 ± 30 rpm in the NEUTRAL position.

2. Engage the lockup clutch by applying power at Tooling (Y) .

3. Check the pressure for the lockup clutch valve at pressure tap (19). The correct pressure must be 2206 ± 138 kPa (320.0 ± 20.0 psi).

4. Record the value in Table 17.

Primary Pressure Check

1. Remove Tooling (Q) .

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Illustration 58	g01208371

2. Remove the load piston plugs (31) from selector valve "A", "B", "C", "E", "G", and "H".

3. Install Tooling (Q) .

4. Adjust the input rotation to 800 ± 30 rpm.

5. Shift the transmission through each gear range.

6. Record the primary clutch pressure for each gear range in Table 18.

7. Verify that the primary clutch pressures match the values in Table 6.

Table 6

Primary Clutch Pressures
Station			"A"	"B"	"C"	"E"	"G"	"H"
Clutch			No. 4	No. 2	No. 1	No. 5	No. 6	No. 3
Speed Range	Engaged Clutches	Pump	Pressure (1)
NEUTRAL	1	3240 kPa (470.0 psi) Minimum pump pressure in all ranges			434 kPa (72 psi)
PARK	4 and 6		710 kPa (103.0 psi)				400 kPa (49 psi)
FORWARD 1	2 and 6			531 kPa (77.0 psi)			400 kPa (49 psi)
FORWARD 2	1 and 6				434 kPa (72 psi)		400 kPa (49 psi)
FORWARD 3	2 and 5			531 kPa (77.0 psi)		531 kPa (77.0 psi)
FORWARD 4	3 and 6						400 kPa (49 psi)	658 kPa (110 psi)
FORWARD 5	1 and 5				434 kPa (72 psi)	531 kPa (77.0 psi)
FORWARD 6	2 and 4		710 kPa (103.0 psi)	531 kPa (77.0 psi)
FORWARD 7	3 and 5					531 kPa (77.0 psi)		658 kPa (110 psi)
FORWARD 8	1 and 4		710 kPa (103.0 psi)		434 kPa (72 psi)

( 1 )

The tolerance is ± 35 kPa (± 5.0 psi).

Pressure Check (High Idle)

1. Remove Tooling (Q) .

2. Install load piston plugs (31) .

3. Install Tooling (Q) .

4. Adjust the input rotation to 1925 ± 30 rpm in NEUTRAL.

5. Record the clutch pressure in Table 19.

6. Record the output speed at Tooling (AA) and the input power on the test bench.

7. Shift the transmission through positions FORWARD 1, FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, FORWARD 7 and FORWARD 8. Repeat Steps 4 through 6 for each gear range.

8. Stop the input rotation to the transmission.

9. Verify that the clutch pressures match the values in Table 7.

Table 7

Pressure Check (High Idle)
Station			"A"	"B"	"C"	"E"	"G"	"H"
Clutch			No. 4 (1)	No. 2 (1)	No. 1 (1)	No. 5 (1)	No. 6 (1)	No. 3 (1)
Speed Range	Engaged Clutches	Pump	Pressure						Output Speed	Max Power Loss
NEUTRAL	1	3240 kPa (470.0 psi) Minimum pump pressure in all ranges			3102 kPa (450.0 psi)
PARK	4 and 6		2413 kPa (350.0 psi)				2944 kPa (427 psi)
FORWARD 1	2 and 6			3137 kPa (455.0 psi)			2944 kPa (427 psi)		577 rpm	91.8 kW (123.1 hp)
FORWARD 2	1 and 6				3102 kPa (450.0 psi)		2944 kPa (427 psi)		785 rpm	101.1 kW (135.6 hp)
FORWARD 3	2 and 5			3137 kPa (455.0 psi)		3309 kPa (480.0 psi)			875 rpm	88.4 kW (118.6 hp)
FORWARD 4	3 and 6						2944 kPa (427 psi)	2413 kPa (391 psi)	1065 rpm	120.4 kW (161.4 hp)
FORWARD 5	1 and 5				3102 kPa (450.0 psi)	3309 kPa (480.0 psi)			1191 rpm	90.7 kW (121.6 hp)
FORWARD 6	2 and 4		2413 kPa (350.0 psi)	3137 kPa (455.0 psi)					1416 rpm	85.9 kW (115.2 hp)
FORWARD 7	3 and 5					3309 kPa (480.0 psi)		2413 kPa (391 psi)	1616 rpm	107.8 kW (144.5 hp)
FORWARD 8	1 and 4		2413 kPa (350.0 psi)		3102 kPa (450.0 psi)				1927 rpm	87.8 kW (117.8 hp)

( 1 )

The tolerance is ± 150 kPa (± 21.7 psi).

Transmission Bench Test Data Sheet

Table 8

CATERPILLAR	Transmission Bench Test Data Sheet	Test Date:
		Model: TH48 - E80
Work Order:		Serial No.:

Solenoid Test

Table 9

Solenoid Test	Upshift Solenoid	Downshift Solenoid
	ohms	ohms

Priority Reducing Valve

Table 10

Priority Reducing Valve

Input Speed (800 ± 30 rpm)

kPa (psi)

Neutralizer Valve

Table 11

Neutralizer Valve (Step 1)			Input Speed (800 ± 30 rpm)
A	B	C	E	F	G	H
kPa (psi)	kPa (psi)	kPa (psi)	kPa (psi)	kPa (psi)	kPa (psi)	kPa (psi)

Table 12

Neutralizer Valve (Step 2)
Gear Range NEUTRAL
Station	C	kPa (psi)	The pressure at Clutch Station (C) must rise to normal pressure.		Yes	No
Gear Range PARK
Station	A	kPa (psi)	Clutch Stations (A) and (G) pressures must rise to normal pressure.		Yes	No
	G	kPa (psi)			Yes	No

Transmission Cooler Inlet Relief Valve

Table 13

Transmission Cooler Inlet Relief Valve

Cooler Outlet Flow 38 ± 0.4 L/min (10 ± 0.1 US gpm)

kPa (psi)

Lube Check (Low Idle)

Table 14

Lube Check (Low Idle)	Input Speed (800 ± 30 rpm)
Gear Range	Lubrication Pressure	Lube Flow
FORWARD 1	kPa (psi)	L/min (US gpm)

Lube Check (High Idle)

Table 15

Lube Check (High Idle)	Input Speed (1925 ± 30 rpm)
Gear Range	Lubrication Pressure	Lube Flow
FORWARD 1	kPa (psi)	L/min (US gpm)
FORWARD 2	kPa (psi)	L/min (US gpm)
FORWARD 3	kPa (psi)	L/min (US gpm)
FORWARD 4	kPa (psi)	L/min (US gpm)
FORWARD 5	kPa (psi)	L/min (US gpm)
FORWARD 6	kPa (psi)	L/min (US gpm)
FORWARD 7	kPa (psi)	L/min (US gpm)
FORWARD 8	kPa (psi)	L/min (US gpm)

Multifunction Manifold Pressures

Table 16

Multifunction Manifold Pressures	Input Speed (1950 ± 30 rpm)
Torque Converter Inlet Pressure	kPa (psi)
Torque Converter Outlet Pressure	kPa (psi)
Speed Increaser Lubrication Pressure	kPa (psi)

Lockup Clutch Pressure

Table 17

Lockup Clutch Pressure

Input Speed (1950 ± 30 rpm)

kPa (psi)

Primary Pressure Check

Table 18

Primary Pressure Check			The Load Piston plugs are removed. Input Speed (800 ± 30 rpm)
Station	Clutch	Specification	Original Pressure	Amount of Adjustment	Last Pressure
A	4	710 kPa (103.0 psi)  (1)
B	2	531 kPa (77.0 psi) (1)
C	1	434 kPa (72.0 psi) (1)
E	5	531 kPa (77.0 psi) (1)
G	6	524 kPa (49.0 psi) (1)
H	3	427 kPa (110.0 psi) (1)

( 1 )

The tolerance is ± 35 kPa (± 5.0 psi).

Pressure Check (High Idle)

Table 19

Pressure Check (High Idle) (1)					Load Piston plugs are installed. Input Speed (1925 ± 30 rpm)
Gear Range	Active Clutches		A	B	C	E	G	H	Output Speed	Power Loss
NEUTRAL	1	-
PARK	4	6
FORWARD 1	2	6
FORWARD 2	1	6
FORWARD 3	2	5
FORWARD 4	3	6
FORWARD 5	1	5
FORWARD 6	2	4
FORWARD 7	3	5
FORWARD 8	1	4

( 1 )

Do not shift the transmission into PARK at any input speed greater than 800 RPM.

ISO Particle Count

Table 20

ISO Particle Count

Sample the test bench oil supply.

________/________Particle Count

Table 21

______________________________________ Technician

______________________________________ Supervisor

Shift Traces

Introduction

Shift traces have become an important tool for validating the proper operation and assembly of the component. The shift cycles are recorded and reviewed in order to analyze the specific segments of the shift cycle. The segments are decay times, fill times, and modulation times. Shift traces can reveal faulty parts or omitted parts. Shift traces can alert the technician to potential problems.

Correct interpretation of terminology is essential for understanding shift traces. Refer to Illustration 60 and Illustration 61 in order to interpret your shift traces correctly.

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 used in order 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.

These averages should be entered on the shift trace worksheets. A typical example is included on each worksheet.

Note: Refer to Table 4 for the required tooling.

Show/hide table



Illustration 59	g01461920
23 - Selector Valve Station A - Clutch 4 24 - Selector Valve Station B - Clutch 2 25 - Selector Valve Station C - Clutch 1 26 - Selector Valve Station E - Clutch 5 27 - Selector Valve Station G - Clutch 6 28 - Selector Valve Station H - Clutch 3

1. Connect a pressure transducer to each of the clutch pressure taps (23), (24), (25), (26), (27), and (28) .

Illustration 60	g00899108
()

Illustration 61	g00899331

Shift Trace NEUTRAL to FORWARD 1

Table 22

Data View Graph Definition
Selected Channels	1, 2, 6
Maximum Pressure	3240 kPa (470.0 psi)
Input Shaft Speed	1925 rpm

Table 23

Channel Assignments
Data Channel		1	2	6
Clutch Station		C	B	G
Sample Rate		100 per sec

Illustration 62	g01219007

Table 24

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	1	.16 sec ± 15%	_____________ sec	_____________ sec
Fill Time	2	.11 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	2	.31 sec ± 15%	_____________ sec	_____________ sec
Fill Time	6	.43 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	6	.35 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 1 to FORWARD 2

Table 25

Data View Graph Definition
Selected Channels	1, 2, 6
Maximum Pressure	3240 kPa (470.0 psi)
Input Shaft Speed	1925 rpm

Table 26

Channel Assignments
Data Channel		1	2	6
Clutch Station		C	B	G
Sample Rate		100 per sec

Illustration 63	g01219010

Table 27

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	2	.16 sec ± 15%	_____________ sec	_____________ sec
Fill Time	1	.18 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	1	.34 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 2 to FORWARD 3

Table 28

Data View Graph Definition
Selected Channels	1, 2, 5, 6
Maximum Pressure	3240 kPa (470.0 psi)
Input Shaft Speed	1925 rpm

Table 29

Channel Assignments
Data Channel		1	2	5	6
Clutch Station		C	B	E	G
Sample Rate		100 per sec

Illustration 64	g01219026

Table 30

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	1	.16 sec ± 15%	_____________ sec	_____________ sec
Decay Time	6	.16 sec ± 15%	_____________ sec	_____________ sec
Fill Time	2	.11 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	2	.31 sec ± 15%	_____________ sec	_____________ sec
Fill Time	5	.12 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	5	.15 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 3 to FORWARD 4

Table 31

Data View Graph Definition
Selected Channels	2, 3, 5, 6
Maximum Pressure	3241 kPa (470.0 psi)
Input Shaft Speed	1925 rpm

Table 32

Channel Assignments
Data Channel		2	3	5	6
Clutch Station		B	H	E	G
Sample Rate		100 per sec

Illustration 65	g01219033

Table 33

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	2	.16 sec ± 15%	_____________ sec	_____________ sec
Decay Time	5	.16 sec ± 15%	_____________ sec	_____________ sec
Fill Time	3	.41 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	3	.42 sec ± 15%	_____________ sec	_____________ sec
Fill Time	6	.43 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	6	.35 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 4 to FORWARD 5

Table 34

Data View Graph Definition
Selected Channels	1, 3, 5, 6
Maximum Pressure	3241 kPa (470.0 psi)
Input Shaft Speed	1925 rpm

Table 35

Channel Assignments
Data Channel		1	3	5	6
Clutch Station		C	H	E	G
Sample Rate		100 per sec

Illustration 66	g01219050

Table 36

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	3	.15 sec ± 15%	_____________ sec	_____________ sec
Decay Time	6	.16 sec ± 15%	_____________ sec	_____________ sec
Fill Time	1	.18 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	1	.34 sec ± 15%	_____________ sec	_____________ sec
Fill Time	5	.12 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	5	.15 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 5 to FORWARD 6

Table 37

Data View Graph Definition
Selected Channels	1, 2, 4, 5
Maximum Pressure	3241 kPa (470.0 psi)
Input Shaft Speed	1925 rpm

Table 38

Channel Assignments
Data Channel		1	2	4	5
Clutch Station		C	B	A	E
Sample Rate		100 per sec

Illustration 67	g01219272

Table 39

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	1	.16 sec ± 15%	_____________ sec	_____________ sec
Decay Time	5	.14 sec ± 15%	_____________ sec	_____________ sec
Fill Time	2	.11 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	2	.31 sec ± 15%	_____________ sec	_____________ sec
Fill Time	4	.16 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	4	.19 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 6 to FORWARD 7

Table 40

Data View Graph Definition
Selected Channels	2, 3, 4, 5
Maximum Pressure	3241 kPa (470.0 psi)
Input Shaft Speed	1925 rpm

Table 41

Channel Assignments
Data Channel		2	3	4	5
Clutch Station		B	H	A	E
Sample Rate		100 per sec

Illustration 68	g01219278

Table 42

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	2	.15 sec ± 15%	_____________ sec	_____________ sec
Decay Time	4	.16 sec ± 15%	_____________ sec	_____________ sec
Fill Time	3	.41 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	3	.42 sec ± 15%	_____________ sec	_____________ sec
Fill Time	5	.12 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	5	.15 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 7 to FORWARD 8

Table 43

Data View Graph Definition
Selected Channels	1, 3, 4, 5
Maximum Pressure	3241 kPa (470.0 psi)
Input Shaft Speed	1925 rpm

Table 44

Channel Assignments
Data Channel		1	3	4	5
Clutch Station		C	H	A	E
Sample Rate		100 per sec

Illustration 69	g01219280

Table 45

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	3	.16 sec ± 15%	_____________ sec	_____________ sec
Decay Time	5	.14 sec ± 15%	_____________ sec	_____________ sec
Fill Time	1	.18 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	1	.34 sec ± 15%	_____________ sec	_____________ sec
Fill Time	4	.16 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	4	.19 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 8 to FORWARD 7

Table 46

Data View Graph Definition
Selected Channels	1, 3, 4, 5
Maximum Pressure	3241 kPa (470.0 psi)
Input Shaft Speed	1265 rpm

Table 47

Channel Assignments
Data Channel		1	3	4	5
Clutch Station		C	H	A	E
Sample Rate		100 per sec

Illustration 70	g01219283

Table 48

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	1	.14 sec ± 15%	_____________ sec	_____________ sec
Decay Time	4	.16 sec ± 15%	_____________ sec	_____________ sec
Fill Time	3	.41 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	3	.42 sec ± 15%	_____________ sec	_____________ sec
Fill Time	5	.12 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	5	.15 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 7 to FORWARD 6

Table 49

Data View Graph Definition
Selected Channels	2, 3, 4, 5
Maximum Pressure	3241 kPa (470.0 psi)
Input Shaft Speed	1265 rpm

Table 50

Channel Assignments
Data Channel		2	3	4	5
Clutch Station		B	H	A	E
Sample Rate		100 per sec

Illustration 71	g01219290

Table 51

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	3	.16 sec ± 15%	_____________ sec	_____________ sec
Decay Time	5	.14 sec ± 15%	_____________ sec	_____________ sec
Fill Time	2	.11 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	2	.31 sec ± 15%	_____________ sec	_____________ sec
Fill Time	4	.16 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	4	.19 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 6 to FORWARD 5

Table 52

Data View Graph Definition
Selected Channels	1, 2, 4, 5
Maximum Pressure	3241 kPa (470.0 psi)
Input Shaft Speed	1265 rpm

Table 53

Channel Assignments
Data Channel		1	2	4	5
Clutch Station		C	B	A	E
Sample Rate		100 per sec

Illustration 72	g01219303

Table 54

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	2	.15 sec ± 15%	_____________ sec	_____________ sec
Decay Time	4	.16 sec ± 15%	_____________ sec	_____________ sec
Fill Time	1	.18 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	1	.34 sec ± 15%	_____________ sec	_____________ sec
Fill Time	5	.12 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	5	.15 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 5 to FORWARD 4

Table 55

Data View Graph Definition
Selected Channels	1, 3, 5, 6
Maximum Pressure	3241 kPa (470.0 psi)
Input Shaft Speed	1265 rpm

Table 56

Channel Assignments
Data Channel		1	3	5	6
Clutch Station		C	H	E	G
Sample Rate		100 per sec

Illustration 73	g01219307

Table 57

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	1	.16 sec ± 15%	_____________ sec	_____________ sec
Decay Time	5	.17 sec ± 15%	_____________ sec	_____________ sec
Fill Time	3	.41 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	3	.42 sec ± 15%	_____________ sec	_____________ sec
Fill Time	6	.43 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	6	.35 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 4 to FORWARD 3

Table 58

Data View Graph Definition
Selected Channels	2, 3, 5, 6
Maximum Pressure	3241 kPa (470.0 psi)
Input Shaft Speed	1265 rpm

Table 59

Channel Assignments
Data Channel		2	3	5	6
Clutch Station		B	H	E	G
Sample Rate		100 per sec

Illustration 74	g01219314

Table 60

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	3	.15 sec ± 15%	_____________ sec	_____________ sec
Decay Time	6	.17 sec ± 15%	_____________ sec	_____________ sec
Fill Time	2	.11 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	2	.31 sec ± 15%	_____________ sec	_____________ sec
Fill Time	5	.12 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	5	.15 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 3 to FORWARD 2

Table 61

Data View Graph Definition
Selected Channels	1, 2, 5, 6
Maximum Pressure	3240 kPa (470.0 psi)
Input Shaft Speed	1265 rpm

Table 62

Channel Assignments
Data Channel		1	2	5	6
Clutch Station		C	B	E	G
Sample Rate		100 per sec

Illustration 75	g01219320

Table 63

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	2	.17 sec ± 15%	_____________ sec	_____________ sec
Decay Time	5	.15 sec ± 15%	_____________ sec	_____________ sec
Fill Time	1	.18 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	1	.34 sec ± 15%	_____________ sec	_____________ sec
Fill Time	6	.43 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	6	.35 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 2 to FORWARD 1

Table 64

Data View Graph Definition
Selected Channels	1, 2, 6
Maximum Pressure	3240 kPa (470.0 psi)
Input Shaft Speed	1265 rpm

Table 65

Channel Assignments
Data Channel		1	2	6
Clutch Station		C	B	G
Sample Rate		100 per sec

Illustration 76	g01219346

Table 66

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	1	.16 sec ± 15%	_____________ sec	_____________ sec
Fill Time	2	.11 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	2	.31 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 1 to NEUTRAL

Table 67

Data View Graph Definition
Selected Channels	1, 2, 6
Maximum Pressure	3240 kPa (470.0 psi)
Input Shaft Speed	1265 rpm

Table 68

Channel Assignments
Data Channel		1	2	6
Clutch Station		C	B	G
Sample Rate		100 per sec

Illustration 77	g01219351

Table 69

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	2	.16 sec ± 15%	_____________ sec	_____________ sec
Decay Time	6	.21 sec ± 15%	_____________ sec	_____________ sec
Fill Time	1	.18 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	1	.34 sec ± 15%	_____________ sec	_____________ sec