Bench Test Procedure for a TA19-4WD Agricultural Tractor Transmission{3030, 3073, 3139} Caterpillar


Bench Test Procedure for a TA19-4WD Agricultural Tractor Transmission{3030, 3073, 3139}

Usage:

TA19-M4WD XAE
Transmission:
TA19 (S/N: XAE1-UP; XAF1-UP)

Introduction

Table 1
Revision     Summary of Changes in REHS3622    
02     Updated arrangement numbers in Table 2.
Updated Introduction.
Added "Think Safety" graphic.    

© 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.

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. 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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Table 2
Sales Model     Transmission Arrangement    
TA19-4WD     317-5322
317-5323    

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 the test bench, use 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.




Illustration 1g02139237

------ WARNING! ------

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.

----------------------

------ WARNING! ------

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

----------------------

------ WARNING! ------

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     1U-9584     Rail As     2    
1U-9585 Block Gp
Transmission Mounting Group    
8    
B     138-7575     Link Bracket     4    
7X-2562 Bolt (16x2x35)     4    
C     1U-9722     Load Binder As
(Ratchet Type)    
2    
D     4C-9032     Plate Adapter     1    
8T-3957 M12x1.75x30mm     4    
(1)     9W-1454     Cover     1    
6V-3966 Nipple Assembly     1    
5P-3863 O-Ring Seal     1    
F     7M-8485     O-Ring Seal     1    
5P-0492 Adapter     1    
8C-9024 Fitting As (PLAIN)     1    
G     6V-3965     Fitting As (Quick Disconnect)     1    
4J-0524 O-Ring Seal     1    
H     277-2363     Transmission Analyzer
Tool Group    
1    
9U-7498 Adapter Cable As
(TRANSMISSION ANALYZER)    
1    
9U-7496 Cable (TEST)     1    
1U-9480 Cable Adapter     9    
K     8T-0855     Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))     10    
8T-0862 Pressure Gauge (−100 to 500 kPa (−15 to 72 psi))     6    
8T-0854 Pressure Gauge (0 to 145 kPa (0 to 145.0 psi))     1    
6V-4144 Coupler     17    
L         O-Ring Seal        
Threaded Flange        
90 degree Nipple (Pipe)        
Threaded Adapter        
Quick Connect        
( 1 ) Refer to Illustration 1.



Illustration 2g02709979

Installation Procedure




    Illustration 3g02711356

  1. Install Tooling (A) on the rails of the test bench, as shown.



    Illustration 4g02711371

  1. Install tooling (B) to the front lift points.



    Illustration 5g02711411



    Illustration 6g02711399

  1. Install tooling (B) to the rear lift points.



    Illustration 7g02711420

  1. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1177 kg (2596.0 lb).



    Illustration 8g02711424

  1. Install Tooling (C) to the front and rear of the transmission.



    Illustration 9g02711438

  1. Install Tooling (D) to the yoke.



    Illustration 10g02711479

  1. Align the transmission with the input drive shaft.

  1. Connect the input drive shaft to Tooling (D) .



    Illustration 11g02711505

  1. Install the drive shaft guard.



    Illustration 12g02711512



    Illustration 13g02711539

  1. Remove cover (1) and install Tooling (E) .



    Illustration 14g02711563



    Illustration 15g02711566

  1. Remove cover (2) and install Tooling (E) .



    Illustration 16g02711573



    Illustration 17g02711569

  1. Remove cover (3) and install Tooling (E) .



    Illustration 18g02711598

  1. Remove plugs (4), (5), and (6).



    Illustration 19g02711620

  1. Install tooling (F) to three locations.



    Illustration 20g02711631

    (7) Charge Pump Supply

  1. Connect hose assembly (7) from the pressurized flow meter to Tooling (F) .

    Note: The flow meter will measure the flow of the supply oil.




    Illustration 21g02711695

    (8) Lubrication Oil Supply

  1. Connect hose assembly (8) from the outlet of the No. 2 flow meter to Tooling (F) .



    Illustration 22g02711728

    (9) Lubrication Oil Supply

  1. Connect hose assembly (9) from Tooling (F) to the inlet of the No. 2 flow meter.

    Note: The No. 2 flow meter will measure oil returning to the test bench.




    Illustration 23g02711756

    (10) Pressure tap for Lubrication Inlet Oil Pressure

  1. Remove dust cap from tap (10) and connect pressure gauge.



    Illustration 24g02711929

  1. Remove plug (11) .



    Illustration 25g02711998

    (12) Pressure Tap for Lubrication Out Oil Pressure

  1. Install Tooling (G) .

  1. Connect a pressure gauge to pressure tap (12) .



    Illustration 26g02712040

    (13) Main Supply Pressure

  1. Remove dust cap from tap (13) and connect a pressure gauge.



    Illustration 27g02712066

    (14) Output Shaft Lubrication Pressure

  1. Connect a pressure gauge to pressure tap (14) .



    Illustration 28g02712072

    (15) Intermediate Shaft Lubrication Pressure

  1. Connect a pressure gauge to pressure tap (15) .



    Illustration 29g02712078

    (16) Reverse Shaft Lubrication Pressure

  1. Connect a pressure gauge to pressure tap (16) .



    Illustration 30g02712169

    (17) Lubrication In Pressure

  1. Connect a pressure gauge to pressure tap (17) .



    Illustration 31g02712131

  1. Remove covers (18) and (19) .



    Illustration 32g02712159

  1. Remove filter.



    Illustration 33g02712225

  1. Install Tooling (L) which directs oil to the sump.



    Illustration 34g02712182

    (20) No. 1 Clutch Control Pressure

    (21) No. 2 Clutch Control Pressure

    (22) No. 3 Clutch Control Pressure

    (23) No. 4 Clutch Control Pressure

    (24) No. 9 Clutch Control Pressure

  1. Remove dust caps and connect pressure gauges to pressure taps (20), (21), (22), (23), and (24) .



    Illustration 35g02712241

    (25) No. 8 Clutch Control Pressure

    (26) No. 7 Clutch Control Pressure

    (27) No. 6 Clutch Control Pressure

    (28) No. 5 Clutch Control Pressure

  1. Remove dust caps and connect pressure gauges to pressure taps (25), (26), (27), and (28) .



    Illustration 36g02712244

  1. Connect Tooling (H) to five clutch solenoids.



    Illustration 37g02712252

  1. Connect Tooling (H) to four clutch solenoids.



    Illustration 38g02712258

  1. Connect Tooling (H) to a suitable location.



    Illustration 39g02712702

  1. Connect Tooling (H) to a power source. Refer to Tool Operating Manual, NEHS0996-00 for the correct operating instructions.

Test Procedure

Solenoid Test

  1. Make sure that the Tooling (H) is properly connected to the transmission.

  1. Use Tooling (H) to perform the solenoid test.

  1. Record the values in Table 11.

Start Checks

  1. If you are using SAE 10W oil, warm the oil to 50 °C (125.0 °F). If you are using Mobil DTE11 oil, warm the oil to 34 °C (95.0 °F). Maintain this temperature for the duration of the test.



    Illustration 40g02712705

    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.

  1. Adjust the supply flow to 120 L/min (31.7 US gpm).

  1. The lubrication pressure must be minimum 137 kPa (20.0 psi).

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

  1. Verify that the active clutches are correct for each gear range. refer to Table 5.

  1. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 rpm.

  1. Verify all test points with the values in Table 4.

  1. Record the values in table 12.

    Note: Tooling (S) has been programmed to ensure that the transmission is shifted sequentially into gear ranges. The functionality of some of the input keys has been changed in order to ensure the requirements of this procedure. Refer to Special Instruction, "Programming Features" for further Information.

  1. Stop the input rotation.

Table 4
Start Checks    

Pump Flow And Pressures
   
Input Speed (700 ± 10 rpm)
Input Flow

120 L/min (31.7 US gpm)    
Gear     Supply Flow     Charge Pressure     Cooler Flow     Lubrication Pressure    
FWD 1    
157 L/min (41.5 US gpm)    

2482 ± 34 kPa (360.0 ± 5.0 psi)    

120 L/min (31.7 US gpm)    

103 ± 69 kPa (15.0 ± 10.0 psi)    
NEUTRAL    
207 ± 83 kPa (30.0 ± 12.0 psi)

Table 5
Transmission Clutch Assignments    
Operation     Clutches    
1 2     3     4     5     6     7     8     9    
FWD
1    
X                 X                    
FWD
2    
    X             X                    
FWD
3    
        X         X                    
FWD
4    
            X     X                    
Neutral                                 X        
REV
1    
                X                 X    
REV
2    
                    X             X    
REV
3    
                        X         X    
REV
4    
                            X     X    

High Idle Checks

Note: Make all shifts from NEUTRAL at 1000 ± 10 rpm.

  1. Adjust the inlet flow to 120 L/min (31.7 US gpm).

  1. Adjust the input rotation to 2100 ± 10 rpm in the NEUTRAL position.

  1. Record the pressures for the active clutches in Table 13.

  1. Record the values in Table 13 for charge pressure, cooler flow, lubrication pressure, clutch leakages, shaft pressures, and output speed and 14 for clutch pressures.

    Note: Calculate clutch leakage by subtracting cooler flow from supply flow.

  1. Verify the test points with the values in Tables 6 and 7.

  1. Shift the transmission through each FORWARD and REVERSE speed range. Repeat steps 1 through 5 for each gear range.

  1. Stop the input rotation.

Table 6
Clutch Pressures    
Gear     Clutch
1    
Clutch
2    
Clutch
3    
Clutch
4    
Clutch
5    
Clutch
6    
Clutch
7    
Clutch
8    
Clutch
9    
FWD 1    
2482 ± 34 kPa (360.0 ± 5.0 psi)    
           
2482 ± 34 kPa (360.0 ± 5.0 psi)    
               
FWD 2        
2482 ± 34 kPa (360.0 ± 5.0 psi)    
       
2482 ± 34 kPa (360.0 ± 5.0 psi)    
               
FWD 3            
2482 ± 34 kPa (360.0 ± 5.0 psi)    
   
2482 ± 34 kPa (360.0 ± 5.0 psi)    
               
FWD 4                
2482 ± 34 kPa (360.0 ± 5.0 psi)    

2482 ± 34 kPa (360.0 ± 5.0 psi)    
               
N                                
2482 ± 34 kPa (360.0 ± 5.0 psi)    
   
REV 1                                
2482 ± 34 kPa (360.0 ± 5.0 psi)    

2482 ± 34 kPa (360.0 ± 5.0 psi)    
REV 2                            
2482 ± 34 kPa (360.0 ± 5.0 psi)    
   
2482 ± 34 kPa (360.0 ± 5.0 psi)    
REV 3                        
2482 ± 34 kPa (360.0 ± 5.0 psi)    
       
2482 ± 34 kPa (360.0 ± 5.0 psi)    
REV 4                    
2482 ± 34 kPa (360.0 ± 5.0 psi)    
           
2482 ± 34 kPa (360.0 ± 5.0 psi)    

Table 7
High Idle Checks     Input Speed (2100 ± 10 rpm)    
Gear     Supply Flow     Charge Pressure
kPa (psi)    
Cooler Flow
L/min (gpm)    
Lubrication Pressure
kPa (psi)    
Leakage    
FWD 1    
120 L/min (31.7 US gpm)    

2482 ± 34 kPa (360 ± 5 psi)    

219 ± 19 L/min (31.7 ± 2.7 US gpm)    

103 ± 69 kPa (15.0 ± 10.0 psi)    

11 ± 3 L/min (3.0 ± 1.0 US gpm)    
FWD 2    
103 ± 69 kPa (15.0 ± 10.0 psi)
FWD 3    
103 ± 69 kPa (15.0 ± 10.0 psi)
FWD 4    
103 ± 69 kPa (15.0 ± 10.0 psi)
N    
193.0 ± 19.0 kPa (28.0 ± 2.8 psi)
REV 1    
103 ± 69 kPa (15.0 ± 10.0 psi)
REV 2    
103 ± 69 kPa (15.0 ± 10.0 psi)
REV 3    
103 ± 69 kPa (15.0 ± 10.0 psi)
REV 4    
103 ± 69 kPa (15.0 ± 10.0 psi)
Gear     Input Shaft Lubrication
kPa (psi)    
Reverse Shaft Lubrication
kPa (psi)    
Intermediate Shaft Lubrication
kPa (psi)    
Output Shaft Lubrication
kPa (psi)    
   
FWD 1    
151 ± 27 kPa (22.0 ± 4.0 psi)    

144 ± 27 kPa (21.0 ± 4.0 psi)    

90 ± 27 kPa (13.0 ± 4.0 psi)    

144 ± 27 kPa (21.0 ± 4.0 psi)    
FWD 2    
151 ± 27 kPa (22.0 ± 4.0 psi)    

151 ± 27 kPa (22.0 ± 4.0 psi)    

103 ± 27 kPa (15.0 ± 4.0 psi)    

144 ± 27 kPa (21.0 ± 4.0 psi)    
FWD 3    
144 ± 27 kPa (21.0 ± 4.0 psi)    

144 ± 27 kPa (21.0 ± 4.0 psi)    

131 ± 27 kPa (19.0 ± 4.0 psi)    

144 ± 27 kPa (21.0 ± 4.0 psi)    
FWD 4    
151 ± 34 kPa (22.0 ± 5.0 psi)    

144 ± 27 kPa (21.0 ± 4.0 psi)    

138 ± 27 kPa (20.0 ± 4.0 psi)    

144 ± 27 kPa (21.0 ± 4.0 psi)    
N    
207 ± 69 kPa (30 ± 10 psi)    

207 ± 69 kPa (30.0 ± 10.0 psi)    

207 ± 69 kPa (30.0 ± 10.0 psi)    

207 ± 69 kPa (30.0 ± 10.0 psi)    
REV 1    
144 ± 27 kPa (21 ± 4 psi)    

138 ± 27 kPa (20.0 ± 4.0 psi)    

131 ± 27 kPa (19.0 ± 4.0 psi)    

144 ± 27 kPa (21.0 ± 4.0 psi)    
REV 2    
144 ± 27 kPa (21 ± 4 psi)    

138 ± 27 kPa (20.0 ± 4.0 psi)    

131 ± 27 kPa (19.0 ± 4.0 psi)    

138 ± 27 kPa (20.0 ± 4.0 psi)    
REV 3    
124 ± 27 kPa (18.0 ± 4.0 psi)    

117 ± 21 kPa (17.0 ± 3.0 psi)    

110 ± 21 kPa (16.0 ± 3.0 psi)    

117 ± 21 kPa (17.0 ± 3.0 psi)    
REV 4    
110 ± 21 kPa (16.0 ± 3.0 psi)    

110 ± 21 kPa (16.0 ± 3.0 psi)    

103 ± 21 kPa (15.0 ± 3.0 psi)    

110 ± 21 kPa (16.0 ± 3.0 psi)    

Lubrication Bypass Check

  1. Adjust the inlet flow to 120 L/min (31.7 US gpm).

  1. Adjust the input rotation to 2100 ± 10 rpm.

  1. Slowly adjust the oil supply to 215 L/min (57.0 US gpm) at tooling (R). At the same time monitor the lubrication bypass pressure.

  1. The lubrication bypass pressure should stabilize at 350 ± 34 kPa (50.8 ± 5.0 psi).

  1. Record the values in table 15.

  1. Stop the input rotation.

Table 8
Lubrication Bypass    
Lubrication Bypass Pressure    
350 ± 34 kPa (50.8 ± 5.0 psi)    

Cooler Bypass Check

  1. Adjust the inlet flow to 120 L/min (31.7 US gpm).

  1. Adjust pressurized flow meter in order to provide 9 L/min (2.5 US gpm) flow to the lubrication supply .

  1. Adjust the input rotation to 2100 ± 10 rpm.

  1. Slowly increase the restriction at the number 2 flow meter by adjusting the flow meter load valve clockwise until the cooler bypass pressure stabilizes.

  1. The cooler bypass pressure should Stabilize at 724 ± 34 kPa (105.0 ± 5.0 psi).

  1. Record the values in table 16.

  1. Stop the input rotation.

Table 9
Cooler Bypass    
Cooler Bypass Pressure    
724 ± 34 kPa (105.0 ± 5.0 psi)    

Contamination Control

  1. Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.

  1. Record the results in Table 17.

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

Transmission Bench Test Data Sheet

Table 10
CATERPILLAR     Transmission Bench Test Data Sheet     Test Date:    
Model:
Work Order:     Serial No.:    

Solenoid Test

Table 11
Solenoid Test     Solenoid 1     Solenoid 2     Solenoid 3     Solenoid 4     Solenoid 5     Solenoid 6     Solenoid 7     Solenoid 8     Solenoid 9    
______
ohms
______
ohms    
______
ohms    
______
ohms    
______
ohms    
______
ohms    
______
ohms    
______
ohms    
______
ohms    

Start Checks

Table 12

Pump Flow And Pressures
   
Input Speed (700 ± 10 rpm)
Input Flow (120 L/min)(31.7 US gpm)    
Oil Temperature     °C (°F)    
Gear     Pump Flow     Charge Pressure     Lubrication Flow     Lubrication Pressure    
FORWARD 1    
______________    

______________    

______________    

______________    
NEUTRAL    
______________    

______________    

______________    

______________    
REVERSE 1    
______________    

______________    

______________    

______________    

Clutch Pressures

Table 13
Clutch Pressures    
Gear     Clutches     Clutch
1    
Clutch
2    
Clutch
3    
Clutch
4    
Clutch
5    
Clutch
6    
Clutch
7    
Clutch
8    
Clutch
9    
FWD 1     8     9                                 _____     _____    
FWD 2     7     9                             _____         _____    
FWD 3     6     9                         _____             _____    
FWD 4     5     9                     _____                 _____    
N     -     8                                 _____        
REV 1     1     5     _____                 _____                    
REV 2     2     5         _____             _____                    
REV 3     3     5             _____         _____                    
REV 4     4     5                 _____     _____                    

High Idle Check

Table 14
High Idle Checks     Input Speed (2100 ± 10 rpm)    
Gear     Supply Flow     Charge Pressure
kPa (psi)    
Cooler Flow
L/min (gpm)    
Lubrication Pressure
kPa (psi)    
Leakage    
FWD 1                        
FWD 2                        
FWD 3                        
FWD 4                        
N                        
REV 1                        
REV 2                        
REV 3                        
REV 4                        
Gear     Input Shaft Lubrication
kPa (psi)    
Reverse Shaft Lubrication
kPa (psi)    
Intermediate Shaft Lubrication
kPa (psi)    
Output Shaft Lubrication
kPa (psi)    
Output Speed    
FWD 1                        
FWD 2                        
FWD 3                        
FWD 4                        
N                        
REV 1                        
REV 2                        
REV 3                        
REV 4                        

Lubrication Bypass Check

Table 15
Lubrication Bypass Check

350 ± 34 kPa (50.8 ± 5 psi)
   
kPa (psi)    

Cooler Bypass Check

Table 16
Cooler Bypass Check

724 ± 34 kPa (105 ± 5 psi)
   
kPa (psi)    

Contamination Control

Table 17
Contamination Control     Sample the test bench oil supply.
   
________/________Particle Count    

Table 18






______________________________________
Technician
   






______________________________________
Supervisor
   

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