Bench Test Procedure For A TH35-E81 Oil/Gas Transmission With A Drop Box {3030} Caterpillar

Petroleum Transmission

TH35-E81 (S/N: MSB1-UP; TZM1-UP; PZT1-UP)

Introduction

© 2015 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 questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. To address an urgent issue, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

• Knowledge Network

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

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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.

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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 used 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.

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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 to develop this test procedure.

Installation Procedure

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1. Install Tooling (A) to the test bench.
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2. Install Tooling (B) to the transmission.
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3. Use a hoist to install the transmission on the test bench. Secure the transmission to Tooling (A). The weight of the transmission is 1361 kg (3000 lb).
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4. Install Tooling (C) to both sides of the transmission.
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5. Install Tooling (D) to Tooling (A) to secure the transmission to the test bench.

   Note: Over-tightening Tooling (D) can jeopardize the tightening ability of the castle nuts on Tooling (A) later in this section.

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6. Install Tooling (E) to the transmission.
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7. Install Tooling (F) to the transmission case.
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8. Install Tooling (G) on Tooling (F).
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9. Tighten the collet on Tooling (G) to connect Tooling (G) to Tooling (E).

   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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10. Install Tooling (H) to the input shaft of Tooling (G).
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11. Install Tooling (J) to the input shaft of Tooling (H).

    Note: Tooling (J) will adapt to the small drive shaft. If you are using the large drive shaft, install Tooling (K) on Tooling (H).

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12. Align the transmission with the input drive shaft.

13. Connect the input drive shaft to Tooling (J).
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14. Install the drive shaft guard.
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15. Tighten all four castle nuts and jack bolts.

16. Re-tighten Tooling (D) to prevent movement during testing.
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17. Install Tooling (L).
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18. Install Tooling (M).
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    (1) Torque Converter Outlet Flow

19. Connect hose assembly (1) from Tooling (L) to the No. 2 flow meter inlet.
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20. Connect hose assembly (2) from the No. 2 flow meter outlet to Tooling (N).
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    (3) Lubrication Oil Flow

21. Connect hose assembly (3) from Tooling (N) to Tooling (M).
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22. Connect lube line (4) from the test bench to Tooling (G). Maintain an oil pressure of 69 kPa (40 psi).
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    (5) Transmission Hydraulic Control Relieve Valve

23. Connect a pressure gauge to pressure tap (5).
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    (6) Torque Converter Inlet Pressure

24. Connect a pressure gauge to pressure tap (6).
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    (7) Transmission Pump Pressure

25. Connect a pressure gauge to pressure tap (7).
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    (8) Latching Rail Pressure

26. Connect a pressure gauge to pressure tap (8).
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    (9) Lockup Clutch Pressure

27. Connect a pressure gauge to pressure tap (9).
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    (10) Torque Converter Outlet Pressure

28. Connect a pressure gauge to pressure tap (10).
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    (11) Lubrication Pressure

29. Connect a pressure gauge to pressure tap (11).
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    (12) Drop Box Lubrication

30. Connect a pressure gauge to pressure tap (12).
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    (13) No. 1 Clutch Pressure (14) No. 2 Clutch Pressure (15) No. 3 Clutch Pressure (16) No. 4 Clutch Pressure (17) No. 5 Clutch Pressure (18) No. 6 Clutch Pressure

31. Connect five pressure gauges to pressure taps (13), (14), (15), (16), (17), and (18).
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    (19) Work Mode Disengage Pressure (20) Work Mode Engage Pressure

32. Connect two pressure gauges to pressure taps (19) and (20).
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    (21) Drive Mode Disengage Pressure (22) Drive Mode Engage Pressure

33. Connect two pressure gauges to pressure taps (21) and (22).
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    Tooling (P)

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34. Connect Tooling (P) to the ECM harness (23).

Test Procedure

TA3 Navigation

1. Select “OEM Transmissions”.

2. Select "TH35FT - 12V - RWD", "TH35FT - 12V - WM", "TH35FT - 24V - RWD", or "TH35FT - 24V - WM".

Harness Test

1. Make sure that the harness is properly connected.

2. Use Tooling (P) to perform the Harness Test which will provide resistance readings for each solenoid.

3. Record the values in Table 6.

   Note: Do not continue testing until Harness Test passes.

Start Checks

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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   Note: The transmission must be in the NEUTRAL position.

2. Rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 800 ± 10 rpm. Hold until the lubrication pressure rises to 14 kPa (2 psi).

   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.

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

4. Verify that the active clutches are correct for each gear range. Refer to Table 4.

5. The lubrication pressure must be 41 ± 28 kPa (6 ± 4 psi).

6. Record the value in Table 7.

Warmup and Low Idle Checks

Note: Make all shifts from NEUTRAL at 800 ± 10 rpm.

1. Adjust the input rotation to 800 ± 10 rpm in the NEUTRAL position.

2. Shift the transmission to FORWARD 1.

3. Shift the transmission through positions FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, FORWARD 7, and FORWARD 8.

4. Downshift the transmission through positions FORWARD 7, FORWARD 6, FORWARD 5, FORWARD 4, FORWARD 3, FORWARD 2, FORWARD 1, and NEUTRAL.

5. Repeat Steps 2 through 4 until the transmission oil reaches a minimum temperature of 47 °C (117 °F).

   Note: The minimum oil temperature of 47 °C (117 °F) must be maintained for two full cycles through the forward gear ranges.

6. Adjust the input rotation to 800 ± 10 rpm in the NEUTRAL position.

7. Shift the transmission through each gear range.

8. Record the values in Table 9 and 11.

9. Verify all test points with the values in Table 8 and Table 10.

High Idle Checks

Note: Make all shifts from NEUTRAL at 800 ± 10 rpm.

1. Adjust the input rotation to 800 ± 10 rpm in the NEUTRAL position.

2. Shift the transmission to REVERSE.

3. Verify that the active clutches are correct for each gear range. Refer to Table 4.

4. Adjust the input rotation to 1900 ± 20 rpm.

5. Record the values in Table 13 and Table 15.

6. Verify all test points with the values in Table 13 and Table 15.

7. Adjust the input rotation to 800 ± 10 rpm.

8. Shift the transmission to NEUTRAL.

9. Shift the transmission to FORWARD 1.

10. Adjust the input rotation to 1900 ± 20 rpm.

11. Record the values in Table 13 and Table 15.

12. Verify all test points with the values in Table 12 and Table 14.

13. Adjust the input rotation to 800 ± 10 rpm.

14. Shift the transmission through the remaining forward ranges. Repeat Steps 10 through 13 for each gear range.

15. With the transmission in FORWARD 8, adjust the input rotation to 1450 ± 25 rpm.

16. Downshift the transmission through FORWARD 7, FORWARD 6, FORWARD 5, FORWARD 4, FORWARD 3, FORWARD 2, FORWARD 1, and NEUTRAL.

17. Adjust the input rotation to 0 rpm.

Pump Flow Check

1. Adjust the input rotation to 800 ± 10 rpm in NEUTRAL.

2. Shift the transmission to FORWARD 2.

3. Increase the input rotation until the cooler flow is equal to 94.6 ± 31 L/min (25 ± 8 US gpm).

4. The lubrication pressure must be 155.1 ± 24.1 kPa (22.5 ± 3.5 psi).

5. The input rotation must be 1900 ± 100 rpm.

6. Record the values in Table 16.

7. Adjust the input rotation to 800 ± 10 rpm.

8. Shift the transmission through FORWARD 1 to the NEUTRAL position.

Drop Box Check

1. Shift the transmission into NEUTRAL and shift the Drop Box into Road Mode.

2. After Road Mode is engaged shift the transmission into FORWARD 3.

3. Adjust the input rotation to 1900 ± 10 rpm.

4. Record the Drop Box Lube, the Engaged Clutch pressure for Road mode, and the Disengaged Clutch pressure for Drawworks Mode in Table 18.

5. Shift the transmission to NEUTRAL.

6. With the transmission in NEUTRAL, shift the Drop box into Drawworks Mode.

7. After Drawworks Mode is engaged shift the transmission into FORWARD 3.

8. Adjust the input rotation to 1900 ± 10 rpm.

9. Record the Drop Box Lube, the Engaged Clutch pressure for Drawworks Mode, and the Disengaged Clutch pressure for Road Mode in Table 20.

10. Shift the transmission to NEUTRAL.

11. Compare the recorded pressures with the pressures in Table 17 and Table 19.

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 21.

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

Transmission Bench Test Data Sheet

Harness Test

Start Checks

Low Idle Checks

High Idle Pressure Checks

Pump Flow Check

Drop Box Check

Contamination Control