- Petroleum Transmission
- TH48-E70 (S/N: KSH1-UP)
Introduction
Revision | Summary of Changes in REHS3435 |
03 | Standardized. |
02 | Added new introduction and Canceled Part Numbers section. |
© 2016 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-specific transmission arrangements. 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. This 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 questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. To address an urgent need, use the following resources to communicate your request to Caterpillar Repair Process Engineering:
- Cat Dealer Techinical Communicator
- Dealer Solution Network
- Cat Technical Representative
- Knowledge Network
Machine Model | Transmission Arrangement |
TH48FT - E70 |
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 additional filtering can affect pressure. The required tools that are listed in Table 3 were used to develop this test procedure. For additional information about tooling, consult Dealer Service Tools Division.
Required Tools | |||
---|---|---|---|
Tool | Part Number | Part Description | Qty |
A | Link Bracket As | 2 | |
Bolt (3/4-10 x 2.75 inch) | 2 | ||
Full Nut | 2 | ||
Hard Washer | 2 | ||
B | Rail As | 2 | |
Block Gp (Transmission Mounting) | 1 | ||
C | Load Binder As (Ratchet Type) | 3 | |
D | Pipe Plug | 2 | |
E | Pipe Plug | 1 | |
F | Pipe Plug | 1 | |
G | Cover Plate | 1 | |
H | Drive Adapter | 1 | |
J | Adapter Ring | 1 | |
Hex Socket Head Screw Bolt (1/2-13 x 2.00 inch) | 4 | ||
Hard Washer | 4 | ||
K | Adapter Plate | 1 | |
Bolt (1/2-13 x 2.00 inch) | 4 | ||
Hard Washer | 4 | ||
L | Spindle Gp | 1 | |
Hex Socket Head Screw Bolt (1/2-13 x 2.00 inch) | 4 | ||
Lockwasher | 4 | ||
M | Adapter (Drive) | 1 | |
N | Drive Adapter (Key)(1) | 1 | |
P | Drive Adapter(2) | 1 | |
Q | 90o Pipe Street Elbow | 1 | |
Pipe Nipple | 1 | ||
R | Plate | 1 | |
Coupler | 1 | ||
S | Fitting | 2 | |
Adapter | 2 | ||
Fitting As (Plain) | 2 | ||
Fitting As (Quick Disconnect) | 2 | ||
Half Flange | 4 | ||
Bolt (7/16-14x1.25 inch) | 8 | ||
Hard Washer | 8 | ||
O-Ring Seal | 1 | ||
O-Ring Seal | 1 | ||
T | Fitting | 1 | |
Adapter | 1 | ||
Half Flange | 2 | ||
Fitting As (Plain) | 1 | ||
Fitting As (Quick Disconnect) | 1 | ||
Bolt (1/2-13x3.25 inch) | 4 | ||
Hard Washer | 4 | ||
U | Fitting | 2 | |
Adapter | 2 | ||
Half Flange | 4 | ||
Fitting As (Plain) | 2 | ||
Fitting As (Quick Disconnect) | 2 | ||
Bolt (7/16-14x1.50 inch) | 8 | ||
Hard Washer | 8 | ||
V | Fitting | 1 | |
Adapter | 1 | ||
Half Flange | 2 | ||
Fitting As (Plain) | 1 | ||
Fitting As (Quick Disconnect) | 1 | ||
Bolt (7/16-14x1.50 inch) | 8 | ||
Hard Washer | 8 | ||
W | Fitting | 1 | |
Tee (Pipe) | 1 | ||
Fitting As (Plain) | 1 | ||
Nipple (Plain) | 1 | ||
Nipple (Pipe) | 1 | ||
Flange (Four Bolt) | 1 | ||
Bushing (Reducing) | 1 | ||
Hex Socket Head Bolt (1/2-13 x 2.00 inch) | 4 | ||
Nipple (Pipe) | 2 | ||
X | Elbow | 1 | |
Flange (Four Bolt) | 1 | ||
Hex Socket Head Bolt (1/2-13 x 2.00 inch) | 4 | ||
Y | Tee (Pipe) | 1 | |
Z | Transmission Analyzer Tool Gp | 1 | |
Extension Cable | 1 | ||
Harness Adapter | 1 | ||
AA | Multitach Tool Gp | 1 | |
Adapter Cable As (Speed Sensor) | 1 | ||
BB | Pressure Gauge (0 to 4,000 kPa (0 to 580 psi)) | 10 | |
Coupler | 10 | ||
CC | Pressure Gauge (0 to 250 kPa (0 to 36 psi)) | 2 | |
Coupler | 2 |
(1) | This drive adapter is used with the small drive shaft. |
(2) | This drive adapter is used with the large drive shaft. |
FT-Drawings
Illustration 3 | g06042214 |
FT-3114 (1) 140-8346 Adapter (2) 281-3075 Cover |
Installation Procedure
- Install Tooling (A) to the output end of the transmission.
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Illustration 5 g01315769 - Install Tooling (B) on the rails of the test bench.
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Illustration 6 g01315770 - Use a hoist to install the transmission on the test bench. The weight of the transmission is
1814 kg (4000 lb) .Show/hide tableIllustration 7 g01315786 - Install Tooling (C).
Note: Overtightening Tooling (C) can jeopardize the tightening ability of castle nuts on Tooling (B) later in this section.
Show/hide tableIllustration 8 g01315795 - Remove threaded drain plug (1).
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Illustration 9 g01315804 - Install Tooling (D).
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Illustration 10 g01315806 - Install Tooling (E).
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Illustration 11 g01315807 - Install Tooling (F).
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Illustration 12 g01315817 - Remove flywheel pilot (2).
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Illustration 13 g01318347 - Remove retaining bolts (3).
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Illustration 14 g01316067 - Install Tooling (G). Tighten retaining bolts (3) to a torque of
120 ± 15 N·m (89 ± 11 lb ft) .Show/hide tableIllustration 15 g01315831 - Install Tooling (H).
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Illustration 16 g01315832 - Install Tooling (J).
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Illustration 17 g01315839 - Install Tooling (K).
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Illustration 18 g01315840 - Install Tooling (L) to Tooling (K).
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Illustration 19 g01315849 - Tighten the collet on Tooling (L) to connect Tooling (L) to Tooling (H).
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.
Show/hide tableIllustration 20 g01315844 - Install Tooling (M) to Tooling (L).
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Illustration 21 g01315846 - Install Tooling (N) to Tooling (M).
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Illustration 22 g01315847 - Align the transmission with the input drive shaft.
- Connect the input drive shaft to Tooling (N).
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Illustration 23 g01315857 - Install the drive shaft guard and secure the drive shaft guard.
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Illustration 24 g03802221 - Tighten all four castle nuts and jack bolts.
- Retighten Tooling (C).
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Illustration 25 g01315860 - Remove threaded plug (4).
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Illustration 26 g01315862 - Install Tooling (Q).
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Illustration 27 g01449877 - Remove cover (5).
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Illustration 28 g01449866 - Install Tooling (R).
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Illustration 29 g01315936 - Install Tooling (S).
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Illustration 30 g01315951 - Install Tooling (T).
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Illustration 31 g01315959 - Install Tooling (U).
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Illustration 32 g01315965 - Install Tooling (V).
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Illustration 33 g01315966 - Install Tooling (W).
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Illustration 34 g01316318 - Install Tooling (X).
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Illustration 35 g01449921 (6) Suction Oil Supply - Install Hose Assembly (6) to Tooling (R).
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Illustration 36 g01316105 (7) Transmission Control Supply Oil - Install Hose Assembly (7) from Tooling (S) to the No. 1 flow meter inlet.
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Illustration 37 g01316106 (8) Transmission Supply Oil - Install Hose Assembly (8) from the No. 1 flow meter outlet to Tooling (T).
Note: The No. 1 flow meter will measure the pump flow to the transmission controls.
Show/hide tableIllustration 38 g01316114 - Install hose Assembly (9) from Tooling (U) to the No. 2 flow meter inlet.
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Illustration 39 g01316340 (10) Cooler Supply Oil - Install Hose Assembly (10) from the No. 2 flow meter outlet to Tooling (W).
Note: The No. 2 flow meter will measure the cooler supply flow.
Show/hide tableIllustration 40 g01316173 - Install Hose Assembly (11) from Tooling (S) to the No. 3 flow meter inlet.
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Illustration 41 g01316351 (12) Torque Converter Inlet Oil - Install Hose Assembly (12) from the No. 3 flow meter outlet to Tooling (W).
Note: The No. 3 flow meter will measure the pump flow to the torque converter.
Show/hide tableIllustration 42 g01316342 (13) Transmission Lubrication Oil - Install Hose Assembly (13) from Tooling (X) to the No. 4 flow meter inlet.
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Illustration 43 g01316276 - Install Tooling (Y) to the No. 4 flow meter outlet.
Note: The No. 4 flow meter will measure the flow in the lube circuit.
Show/hide tableIllustration 44 g01316367 - Install Hose Assembly (14) from Tooling (Y) to Tooling (V).
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Illustration 45 g01316368 - Install Hose Assembly (15) from Tooling (Y) to Tooling (U).
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Illustration 46 g01316372 - Connect Hose Assembly (16) from the auxiliary oil supply at the test bench to Tooling (L). Maintain an oil pressure of
275 kPa (40 psi) .Show/hide tableIllustration 47 g01316373 (17) Transmission Lubrication Pressure - Connect a pressure gauge to test port (17).
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Illustration 48 g01316375 (18) Lubrication Relief Valve Pressure - Connect a pressure gauge to test port (18).
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Illustration 49 g01316376 (19) Torque Converter Inlet Pressure - Connect a pressure gauge to test port (19).
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Illustration 50 g01316377 (20) Torque Converter Outlet Pressure - Connect a pressure gauge to test port (20).
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Illustration 51 g01316378 (21) Lockup Clutch Pressure - Connect a pressure gauge to test port (21).
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Illustration 52 g01316571 (22) No. 6 Clutch Pressure
(23) No. 5 Clutch Pressure
(24) No. 4 Clutch Pressure
(25) No. 2 Clutch Pressure
(26) No. 3 Clutch Pressure
(27) No. 1 Clutch Pressure - Connect a pressure gauge to each of the clutch pressure taps (22), (23), (24), (25), (26), and (27).
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Illustration 53 g01316615 (28) Supply Pressure - Connect a pressure gauge to pressure tap (28).
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Illustration 54 g01316619 (29) Torque Converter Inlet Pressure - Connect a pressure gauge to pressure tap (29).
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Illustration 55 g01337983 Tooling (Z) Show/hide tableIllustration 56 g01451538 Show/hide tableIllustration 57 g01318003 - Install Tooling (Z).
Illustration 4 | g01315763 |
TA3 Navigation
- Select “OEM Transmissions”.
- Select “TH48FT - E70-24V”.
Harness Test
- Make sure that Tooling (Z) is properly connected.
- Use Tooling (Z) to perform the harness test.
- Record the values in Table 6.
Note: Do not continue testing until Harness Test passes.
Start Checks
- Use SAE 10W oil and warm to
50 °C (125 °F) . Maintain this temperature for the duration of the test.Show/hide tableIllustration 58 g02720621 - With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 10 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.
- The lubrication pressure must be
79 ± 28 kPa (12 ± 4 psi) .Note: If there is no lube pressure after 3 seconds, stop input rotation and check connections on test bench and transmission.
- Shift the transmission through all gears to eliminate air from the transmission controls.
- Confirm clutch engagement with Table 4.
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Table 4 Clutch Engagement Check Gear Cl 1 Cl 2 Cl 3 Cl 4 Cl 5 Cl 6 Cl 7 N X PARK X X F1 X X F2 X X F3 X X F4 X X F5 X X F6 X X F7 X X - Stop the input rotation.
Note: Refer to Testing and Adjusting, KENR5689, "TH48FT - E70 Oil Field Transmission Power Train" for the correct adjusting procedures.
Lube Check
- Adjust the input rotation to 700 ± 10 rpm.
- Shift the transmission to FORWARD 2.
- Adjust the input rotation to obtain a cooler flow of
189 ± 4 L/min (50 ± 1 US gpm) . - Record the lubrication pressure in Table 7.
(Reference:
138 ± 35 kPa (20 ± 5 psi) ) - Record the supply pressure in Table 7.
(Reference:
2930 ± 103 kPa (425 ± 15 psi) ) - Shift the transmission to FORWARD 1.
- Adjust the input rotation to 2100 ± 10 rpm.
- Record the lubrication pressure in Table 8.
(Reference:
241 ± 35 kPa (35 ± 5 psi) ) - Record the lube flow in Table 8.
(Reference:
239 ± 19 L/min (63± 5 US gpm) ) - Shift the transmission through positions FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, and FORWARD 7. Repeat Steps 7 through 9 for each gear range.
Pressure Check (Low Idle)
- Adjust the input rotation to 700 ± 10 rpm in the NEUTRAL position.
- Record the clutch pressure in Table 10.
- Record the output speed at Tooling (AA) and the input power on the test bench in Table 10.
- Shift the transmission through positions PARK, FORWARD 1, FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, and FORWARD 7. Repeat Steps 1 through 3 for each gear range.
- Stop the input rotation.
- Verify that the clutch pressures match the values in Table 9.
Pressure Check (High Idle)
- Adjust the input rotation to 2100 ± 10 rpm in the NEUTRAL position.
- Record the clutch pressure in Table 12.
- Record the output speed at Tooling (AA) and the input power on the test bench in Table 12.
- Adjust the input rotation to 700 ± 10 rpm.
- Shift the transmission through positions FORWARD 1, FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, and FORWARD 7. Repeat Steps 1 through 4 for each gear range.
- Stop the input rotation.
- Verify that the clutch pressures match the values in Table 11.
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 13.
- 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.:_______ |
Solenoid Test
Solenoid Test | Solenoid 1 | Solenoid 2 | Solenoid 3 | Solenoid 4 | Solenoid 5 | Solenoid 6 | Solenoid 7 |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
_______ ohms |
Lube Check (Low Idle)
Lube Check (Low Idle) |
Input Speed (700 ± 10 rpm) | |
Gear | Lubrication Pressure | Lube Flow |
f1 |
_______kPa _______(psi) |
_______L/min _______(US gpm) |
Lube Check (High Idle)
Lube Check (High Idle) |
Input Speed (2100 ± 10 rpm) | |
---|---|---|
Gear Range | Lubrication Pressure | Lube Flow |
F1 |
_______kPa _______(psi) |
_______L/min _______(US gpm) |
F2 |
_______kPa _______(psi) |
_______L/min _______(US gpm) |
F3 |
_______kPa _______(psi) |
_______L/min _______(US gpm) |
F4 |
_______kPa _______(psi) |
_______L/min _______(US gpm) |
F5 |
_______kPa _______(psi) |
_______L/min _______(US gpm) |
F6 |
_______kPa _______(psi) |
_______L/min _______(US gpm) |
F7 |
_______kPa _______(psi) |
_______L/min _______(US gpm) |
Pressure Check (Low Idle)
Pressure Check (Low Idle) | ||||||||||
---|---|---|---|---|---|---|---|---|---|---|
Gear | Engaged Clutches | Pump | Cl 1(1) | Cl 2(1) | Cl 3(1) | Cl 4(1) | Cl 5(1) | Cl 6(1) | Output Speed(2) | Max Power Loss |
N | 1 | |
|
|
||||||
PARK | 4 and 6 | |
|
|
||||||
F1 | 2 and 6 | |
|
114 rpm | |
|||||
F2 | 1 and 6 | |
|
155 rpm | |
|||||
F3 | 3 and 6 | |
|
210 rpm | |
|||||
F4 | 1 and 5 | |
|
284 rpm | |
|||||
F5 | 3 and 5 | |
|
385 rpm | |
|||||
F6 | 1 and 4 | |
|
515 rpm | |
|||||
F7 | 3 and 4 | |
|
700 rpm | |
(1) | The tolerance is |
(2) | The tolerance is ± 10 rpm. |
Pressure Check (Low Idle)(1) | Input Speed (700 ± 10 rpm) | |||||||||
---|---|---|---|---|---|---|---|---|---|---|
Gear | Active Clutches | Cl 1 | Cl 2 | Cl 3 | Cl 4 | Cl 5 | Cl 6 | Output Speed | Power Loss | |
N | 1 | - | ||||||||
PARK | 4 | 6 | ||||||||
F1 | 2 | 6 | ||||||||
F2 | 1 | 6 | ||||||||
F3 | 3 | 5 | ||||||||
F4 | 1 | 5 | ||||||||
F5 | 3 | 5 | ||||||||
F6 | 1 | 4 | ||||||||
F7 | 3 | 4 |
(1) | Do not shift the transmission into PARK at any input speed greater than 800 RPM. |
Pressure Check (High Idle)
Pressure Check (High Idle) | ||||||||||
---|---|---|---|---|---|---|---|---|---|---|
Gear | Engaged Clutches | Pump | Cl 1(1) | Cl 2(1) | Cl 3(1) | Cl 4(1) | Cl 5(1) | Cl 6(1) | Output Speed(2) | Max Power Loss |
N | 1 | |
|
|
||||||
F1 | 2 and 6 | |
|
343 rpm | |
|||||
F2 | 1 and 6 | |
|
466 rpm | |
|||||
F3 | 3 and 6 | |
|
632 rpm | |
|||||
F4 | 1 and 5 | |
|
852 rpm | |
|||||
F5 | 3 and 5 | |
|
1154 rpm | |
|||||
F6 | 1 and 4 | |
|
1550 rpm | |
|||||
F7 | 3 and 4 | |
|
2102 rpm | |
(1) | The tolerance is |
(2) | The tolerance is ± 10 rpm. |
Pressure Check (High Idle)(1) | Input Speed (2100 ± 10 rpm) | |||||||||
---|---|---|---|---|---|---|---|---|---|---|
Gear | Active Clutches | Cl 1 | Cl 2 | Cl 3 | Cl 4 | Cl 5 | Cl 6 | Output Speed | Power Loss | |
N | 1 | - | ||||||||
F1 | 2 | 6 | ||||||||
F2 | 1 | 6 | ||||||||
F3 | 3 | 5 | ||||||||
F4 | 1 | 5 | ||||||||
F5 | 3 | 5 | ||||||||
F6 | 1 | 4 | ||||||||
F7 | 3 | 4 |
(1) | Do not shift the transmission into PARK at any input speed greater than 800 RPM. |
Contamination Control
ISO Particle Count | Sample the test bench oil supply. *ISO 4406 is 16/13 or better |
________/________Particle Count |
______________________________________ Technician |
______________________________________ Supervisor |