Bench Test Procedure for a CX48-P2300 Transmission {0599, 0717, 3003, 3030, 3101, 3159} Caterpillar

Petroleum Transmission

CX48-P2300 (S/N: GDH1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS3639
05	Updated Clutch Engagement, Table 4.
04	Updated Hose Assembly Installation. Standardized.
03	Updated Tool Table 3. Updated Introduction.
02	Updated Tool Table 3.
01	Updated Table 7 and Pressure Check steps.
00	Converted to SIS Authoring Format.

© 2017 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This special instruction contains the necessary information that is required to bench test-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 action 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:

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Table 2

Machine Model	Transmission Arrangement
CX48-P2300	394-5695, 439-4770, 359-5427, 388-8735, 388-8745, 388-8750, 388-8755, 388-8760, 394-5700, 394-5705, 419-5650, 419-5655

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 in order 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 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.

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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

Pressures will be sensitive to tooling setup. The diameter of the hose, the diameter of a fitting, and extra filtering can affect pressure. The required tools that are listed in Table 3 were used to develop this test procedure. These tools are suggested and may very depending on availability and bench configuration.

Table 3

Tooling	Tool Number	Part Description	Qty
A	1U-9584	Rail As	2
	439-5592(1)	Rail As	2
	439-5591	Plate (upright support)	2
	5P-8248	Hard Washer (3/4 inch)	4
	9X-8885	Bolt (3/4-10x2.25 inch)	4
	395-1098	Eye Bolt	4
	439-3938	Link Bracket	2
B	1U-5119	Adapter Ring	1
C	439-5589	Drive Adapter	1
D	283-5010	Spindle Adapter	1
	5P-2566	Bolt (1/2-13X1.50 inch)	8
	8T-4223	Hard Washer	8
E	1U-5999	Spindle Gp	1
	8B-7997	Bolt (1/2-13X2.0 inch)	4
	3B-4506	Lockwasher	4
F	1U-6721	Adapter As	1
G	1U-9131	Drive Adapter	1
H	1U-9722	Load Binder As (Ratchet type)	2
J	321-2561	Plate	2
K	5B-7666	Elbow	4
	4J-0524	O-Ring Seal	4
	152-9844	Reducer	4
	1U-9870	Flange	4
	9U-7446	Adapter	4
	1U-8301	Fitting	4
	1P-4579	Half Flange	8
	3F-7147	Bolt	8
	6V-3965	Fitting	4
	8C-9024	Fitting As	4
L	8C-9032	Nipple As	2
	1U-9873	4-Bolt Flange (2 NPTF)	2
	222-1110	Seal-O-ring	2
	2F-5277	Reducing Bushing	2
	144-8618	Adapter	2
M	357-4381	Connector As	1
N	311-4929	Cable As	1
	306-0397	Adapter Cable As (TA3 Extension Cable)	1
P	277-2363	Transmission Analyzer Gp	1
Q(2)	4C-9910	Portable Hydraulic Tester	3
R(2)	8T-0854	Pressure Gauge ( 993 kPa (144 psi))	1
S(2)	8T-0855	Pressure Gauge ( 3447 kPa (500 psi))	10

(1)	Use if the test bench is flush with the floor
(2)	Optional Tooling if needed with Test Bench

Installation Procedure

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Illustration 3	g03378998

1. Install Tooling (A) to Test Bench.
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   Illustration 4	g03874708

2. Remove drain plug from the bottom of the transmission to allow oil to drain.

   Note: Do not remove ecology drain. Pump cavitation may occur.

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   Illustration 5	g03381352

3. Install Tooling (A) to lift the transmission.
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   Illustration 6	g03379410

4. Install Tooling (A) on the output end of the transmission.
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   Illustration 7	g03379421

5. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1633 kg (3600 lb).
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   Illustration 8	g03379515

6. Remove 359-7760 359-7761 Adapter As from the transmission.
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   Illustration 9	g03379541

7. Install Tooling (B) on the transmission.
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   Illustration 10	g03379626

8. Install Tooling (C) in place of 359-7760 359-7761 Adapter As.

   Note: Use the same bolts removed in Step 6.

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   Illustration 11	g03872841

9. Install Tooling (D) onto Tooling (B).

   Note: Position the access window straight to the bottom for Torque Converter drainage.

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   Illustration 12	g03379660

10. Install Tooling (E) onto Tooling (D).
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    Illustration 13	g03374665

11. Adjust and tighten the collet on Tooling (E).

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

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    Illustration 14	g03379674

12. Install Tooling (F) onto Tooling (E).
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    Illustration 15	g03379684

13. Install Tooling (G) onto Tooling (F).
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    Illustration 16	g03379693

14. Align the transmission to the input drive shaft.

15. Connect the input drive shaft to Tooling (G).
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    Illustration 17	g03374951

16. Close and latch drive shaft guard.
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    Illustration 18	g03388707

17. Tighten Jack Bolts and Castle Nuts.
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    Illustration 19	g03381559

18. Install Tooling (H) to the input and output end of the transmission to prevent movement of the transmission during the test.
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    Illustration 20	g03380111

19. Install Tooling (J) to transmission.

    Note: Remove manifold and install Tooling (J) with tube and O-rings.

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    Illustration 21	g03380272

20. Install Tooling (K) onto Tooling (J).

    Note: All four adapters can be the same part numbers.

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    Illustration 22	g03380333

21. Install Tooling (L) to the Torque Converter (in) port and the Torque Converter (out) port on the transmission.
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    Illustration 23	g03380723

22. Install Tooling (M) to Transmission Sump Fill.
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    Illustration 24	g03380768

23. Connect Lubrication Line (1) from Test Bench Bearing Lube Supply to Tooling (E). Adjust Bearing Lube until 276 kPa (40 psi) is achieved.

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

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    Illustration 25	g03380781
    Transmission Sump Fill

24. Connect Hose Assembly (2) from gravity feed off the bench to Tooling (M).
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    Illustration 26	g03380811
    (3) Filter (out) flow/Transmission Pump Flow

25. Connect Hose Assembly (3) from Tooling (K) to Flowmeter 3 (in).
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    Illustration 27	g03380876
    (4) Controls (in) flow

26. Connect Hose Assembly (4) from Flowmeter 3 (out) to Tooling (K).
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    Illustration 28	g03380892
    (5) Controls (out) flow

27. Connect Hose Assembly (5) from Tooling (K) to Flowmeter 1 (in).
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    Illustration 29	g03380919
    (6) Torque Converter (in) flow

28. Connect Hose Assembly (6) from Flowmeter 1 (out) to Tooling (L).
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    Illustration 30	g03380930
    (7) Torque Converter (out) flow

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    Illustration 31	g03865700
    (7) Lube (in) flow

29. Connect Hose Assembly (7) from Tooling (L) to Tooling (K).
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    Illustration 32	g03380962
    0 - 3447 kPa (0 - 500 psi) (9) No. 3 clutch (10) No. 4 clutch (11) No. 1 clutch (12) No. 6 clutch (13) No. 5 clutch (14) No. 2 clutch

30. Connect Pressure Gauges to Pressure Taps (9-14).
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    Illustration 33	g03383203
    0 - 3447 kPa (0 - 500 psi) (15) Torque Converter (in) pressure

31. Connect a Pressure Gauge to Pressure Tap (15).
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    Illustration 34	g03380974
    0 - 965 kPa (0 - 140 psi) (16) Lube (in) pressure

32. Connect a Pressure Gauge to Pressure Tap (16).
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    Illustration 35	g03380988
    0 - 3447 kPa (0 - 500 psi) (17) Controls (in) pressure

33. Connect a Pressure Gauge to Pressure Tap (17).
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    Illustration 36	g03381000
    0 - 3447 kPa (0 - 500 psi) (18) Lock-up clutch pressure

34. Connect a Pressure Gauge to Pressure Tap (18).
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    Illustration 37	g03381016
    0 - 3447 kPa (0 - 500 psi) (19) Torque Converter (Out) pressure

35. Connect a Pressure Gauge to Pressure Tap (19).
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    Illustration 38	g03381576

36. Install Tooling (N) to ECM on transmission.
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    Illustration 39	g03381578

37. Connect Tooling (N) to Tooling (P).

38. Connect Tooling (P) to a power source. Refer to Tool Operating Manual, NEHS0996 for the correct operating instructions.

Test Procedure

TA3 Navigation

1. Select “OEM Transmissions”.

2. Select “CX48-24V”.

Harness Test

1. Make sure that Tooling (N) is properly connected.

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

3. Record Values in Table 6.

   Note: If Harness Test fails, do not proceed with the Transmission Test.

Start Checks

1. Use Caterpillar approved SAE 10W oil. Warm the oil to 52 °C (125.0 °F). If Mobil DTE11 oil is being used, warm the oil to 35 °C (95 °F). Maintain this temperature for the duration of the test.

2. Open Gravity Feed until the correct oil level is maintained in the transmission sight glass.
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   Illustration 40	g02720621

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

4. Verify that system pressure, lubrication pressure, and pump flow fall within the values in Table 7.

   Note: If there is no lube pressure after 30 seconds, stop input rotation and check connections on test bench and transmission.

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

6. Ensure clutch engagement with Table 4.
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   Table 4

   Clutch Engagement
   Gear	Cl 1	Cl 2	Cl 3	Cl 4	Cl 5	Cl 6	Lockup
   P				X		X
   N	X
   F1		X				X	X
   F2	X					X	X
   F3		X			X		X
   F4			X			X	X
   F5	X				X		X
   F6		X		X			X
   F7			X		X		X
   F8	X			X

7. With the transmission in the NEUTRAL position, adjust the input rotation to 1900 RPM.

8. Verify that system pressure, lubrication pressure, and pump flow fall within the values in Table 7.

9. Reduce the input rotation to 700 rpm.

Low Idle Pressure Check

1. Adjust the input rotation to 700 ± 30 RPM.

2. Verify that the correct oil level is maintained in the transmission sight glass.

3. Shift the transmission into FORWARD 1.

4. Record all pressures in Table 9.

5. Record all flows in Table 14.

6. Repeat Steps 3 through 5 for all gear ranges.

Medium Idle Pressure Check

1. Adjust the input rotation to 700 rpm.

2. Shift the transmission into FORWARD 1.

3. Adjust the input rotation to 1400 ± 30 rpm.

4. Verify that the correct oil level is maintained in the transmission sight glass.

5. Record all pressures in Table 11.

6. Record all flows in Table 15.

7. Repeat Steps 1 through 6 for all gear ranges.

High Idle Pressure Check

1. Adjust the input rotation to 700 rpm.

2. Shift the transmission into FORWARD 1.

3. Adjust the input rotation to 1900 ± 30 rpm.

4. Verify that the correct oil level is maintained in the transmission sight glass.

5. Record all pressures in Table 13.

6. Record all flows in Table 16.

7. Repeat Steps 1 through 6 for all gear ranges.

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 17.

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

Transmission Bench Test Data Sheet

Table 5

Caterpillar	Transmission Bench Test Data Sheet	Test Date:__________________
		Model:_____________________
Work Order:____________________________________________		Serial No.:__________________

Harness Test

Table 6

Harness Test	Solenoid 1	Solenoid 2	Solenoid 3	Solenoid 4	Solenoid 5	Solenoid 6
	________ Ohms	________ Ohms	________ Ohms	________ Ohms	________ Ohms	________ Ohms

Start Checks

Table 7

Test Point	Low	High
Main Pressure	2344 kPa (340 psi)	2551 kPa (370 psi)
Lubrication Pressure	34 kPa (5 psi)	103 kPa (15 psi)
Pump Flow	94.6 ± 9.5 L/min (25 ± 2.5 US gpm)	280 ± 11.4 L/min (74 ± 3 US gpm)

Low, Medium, and High Idle Pressures

Table 8

Low Idle Pressure @ 700 rpm
C	1	2	3	4	5	6	TC In	Lube In	Ctrl In	Lockup	TC Out
P				2310 kPa (335 psi)		2551 kPa (370 psi)	103 kPa (15 psi)	41 kPa (6 psi)	2689 kPa (390 psi)		55 kPa (8 psi)
N	2586 kPa (375 psi)						103 kPa (15 psi)	48 kPa (7 psi)	2689 kPa (390 psi)		69 kPa (10 psi)
1F		2482 kPa (360 psi)				2482 kPa (360 psi)	103 kPa (15 psi)	48 kPa (7 psi)	2551 kPa (370 psi)	2310 kPa (335 psi)	69 kPa (10 psi)
2F	2482 kPa (360 psi)					2482 kPa (360 psi)	103 kPa (15 psi)	48 kPa (7 psi)	2551 kPa (370 psi)	2310 kPa (335 psi)	69 kPa (10 psi)
3F		2482 kPa (360 psi)			2482 kPa (360 psi)		103 kPa (15 psi)	48 kPa (7 psi)	2551 kPa (370 psi)	2310 kPa (335 psi)	69 kPa (10 psi)
4F			2482 kPa (360 psi)			2448 kPa (355 psi)	103 kPa (15 psi)	48 kPa (7 psi)	2551 kPa (370 psi)	2310 kPa (335 psi)	69 kPa (10 psi)
5F	2482 kPa (360 psi)				2482 kPa (360 psi)		103 kPa (15 psi)	48 kPa (7 psi)	2551 kPa (370 psi)	2310 kPa (335 psi)	69 kPa (10 psi)
6F		2448 kPa (355 psi)		2241 kPa (325 psi)			83 kPa (12 psi)	34 kPa (5 psi)	2551 kPa (370 psi)	2310 kPa (335 psi)	55 kPa (8 psi)
7F			2448 kPa (355 psi)		2448 kPa (355 psi)		97 kPa (14 psi)	41 kPa (6 psi)	2551 kPa (370 psi)	2310 kPa (335 psi)	62 kPa (9 psi)
8F	2482 kPa (360 psi)			2241 kPa (325 psi)			103 kPa (15 psi)	48 kPa (7 psi)	2551 kPa (370 psi)	2310 kPa (335 psi)	69 kPa (10 psi)

Note: Tolerance for clutch 1 through 6 and lockup is ± 103 kPa (15 psi).

Table 9

700 RPM Pressure Check
C	1	2	3	4	5	6	TC In	Lube	Controls In	Lockup	TC Out
P	X	X	X		X					X
N		X	X	X	X	X				X
1F	X		X	X	X
2F		X	X	X	X
3F	X		X	X		X
4F	X	X		X	X
5F		X	X	X		X
6F	X		X		X	X
7F	X	X		X		X
8F		X	X		X	X

Table 10

Medium Idle Pressure @ 1400 rpm
C	1	2	3	4	5	6	TC In	Lube In	Ctrl In	Lockup	TC Out
P
N
1F		2689 kPa (390 psi)				2689 kPa (390 psi)	379 kPa (55 psi)	159 kPa (23 psi)	2999 kPa (435 psi)	2448 kPa (355 psi)	221 kPa (32 psi)
2F	2689 kPa (390 psi)					2689 kPa (390 psi)	379 kPa (55 psi)	159 kPa (23 psi)	2999 kPa (435 psi)	2448 kPa (355 psi)	221 kPa (32 psi)
3F		2689 kPa (390 psi)			2689 kPa (390 psi)		379 kPa (55 psi)	159 kPa (23 psi)	2999 kPa (435 psi)	2448 kPa (355 psi)	241 kPa (35 psi)
4F			2689 kPa (390 psi)			2689 kPa (390 psi)	379 kPa (55 psi)	159 kPa (23 psi)	2999 kPa (435 psi)	2448 kPa (355 psi)	221 kPa (32 psi)
5F	2689 kPa (390 psi)				2689 kPa (390 psi)		379 kPa (55 psi)	159 kPa (23 psi)	2999 kPa (435 psi)	2448 kPa (355 psi)	221 kPa (32 psi)
6F		2689 kPa (390 psi)		2379 kPa (345 psi)			359 kPa (52 psi)	138 kPa (20 psi)	2999 kPa (435 psi)	2448 kPa (355 psi)	200 kPa (29 psi)
7F			2689 kPa (390 psi)		2689 kPa (390 psi)		379 kPa (55 psi)	159 kPa (23 psi)	2999 kPa (435 psi)	2448 kPa (355 psi)	221 kPa (32 psi)
8F	2689 kPa (390 psi)			2379 kPa (345 psi)			359 kPa (52 psi)	138 kPa (20 psi)	2999 kPa (435 psi)	2448 kPa (355 psi)	200 kPa (29 psi)

Note: Tolerance for clutch 1 through 6 and lockup is ± 103 kPa (15 psi).

Table 11

1400 RPM Pressure Check
C	1	2	3	4	5	6	TC In	Lube	Controls In	Lockup	TC Out
P	X	X	X	X	X	X	X	X	X	X	X
N	X	X	X	X	X	X	X	X	X	X	X
1F	X		X	X	X
2F		X	X	X	X
3F	X		X	X		X
4F	X	X		X	X
5F		X	X	X		X
6F	X		X		X	X
7F	X	X		X		X
8F		X	X		X	X

Table 12

High Idle Pressure @ 1900 rpm
C	1	2	3	4	5	6	TC In	Lube In	Ctrl In	Lockup	TC Out
P
N
1F		2758 kPa (400 psi)				2758 kPa (400 psi)		303 kPa (44 psi)	3103 kPa (450 psi)	2448 kPa (355 psi)	627 kPa (91 psi)
2F	2758 kPa (400 psi)					2758 kPa (400 psi)		303 kPa (44 psi)	3103 kPa (450 psi)	2448 kPa (355 psi)	600 kPa (87 psi)
3F		2758 kPa (400 psi)			2758 kPa (400 psi)			290 kPa (42 psi)	3047 kPa (442 psi)	2448 kPa (355 psi)	607 kPa (88 psi)
4F			2758 kPa (400 psi)			2758 kPa (400 psi)		290 kPa (42 psi)	3034 kPa (440 psi)	2448 kPa (355 psi)	627 kPa (91 psi)
5F	2758 kPa (400 psi)				2758 kPa (400 psi)			296 kPa (43 psi)	3068 kPa (445 psi)	2448 kPa (355 psi)	607 kPa (88 psi)
6F		2758 kPa (400 psi)		2344 kPa (340 psi)				255 kPa (37 psi)	3068 kPa (445 psi)	2448 kPa (355 psi)	538 kPa (78 psi)
7F			2758 kPa (400 psi)		2758 kPa (400 psi)			290 kPa (42 psi)	3068 kPa (445 psi)	2448 kPa (355 psi)	586 kPa (85 psi)
8F	2758 kPa (400 psi)			2344 kPa (340 psi)				255 kPa (37 psi)	3047 kPa (442 psi)	2448 kPa (355 psi)	552 kPa (80 psi)

Note: Tolerance for clutch 1 through 6 and lockup is ± 103 kPa (15 psi).

Table 13

1900 RPM Pressure Check
C	1	2	3	4	5	6	TC In	Lube	Controls In	Lockup	TC Out
P	X	X	X	X	X	X	X	X	X	X	X
N	X	X	X	X	X	X	X	X	X	X	X
1F	X		X	X	X
2F		X	X	X	X
3F	X		X	X		X
4F	X	X		X	X
5F		X	X	X		X
6F	X		X		X	X
7F	X	X		X		X
8F		X	X		X	X

Low, Medium, and High Idle Flows

Table 14

Low Idle @ 700 rpm
Gear	Transmission Pump Flow	Control Out Flow
Neutral
1F
2F
3F
4F
5F
6F
7F
8F

Table 15

Medium Idle @ 1400 rpm
Gear	Transmission Pump Flow	Control Out Flow
Neutral
1F
2F
3F
4F
5F
6F
7F
8F

Table 16

High Idle @ 1900 rpm
Gear	Transmission Pump Flow	Control Out Flow
Neutral
1F
2F
3F
4F
5F
6F
7F
8F

ISO Particle Count

Table 17

ISO Particle Count

Sample the test bench oil supply. **ISO 4406 is 16/13 or better.**

________ / ________ Particle Count

Table 18

Technician______________________________________

Supervisor____________________________________