Bench Test Procedure For A 35, 45, and 55 Challenger Transmission {3030, 3073} Caterpillar

Challenger

35 (S/N: 9DF1-UP; 8DN1-849)

45 (S/N: 1DR1-1699; 4DZ1-UP)

55 (S/N: 5DK1-UP; 7DM1-849)

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- 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 issue, 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

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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Illustration 3	g01222527

1. Install Tooling (A).

2. Use a hoist to install the transmission. The weight of the transmission is 928 kg (2045 lb).
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3. Install Tooling (B).
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4. Align the transmission with the input drive shaft.

5. Connect the input drive shaft to Tooling (B).
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6. Install the drive shaft guard.
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7. Tighten all four castle nuts and jack bolts.

8. Fasten the transmission to the test bench by using Tooling (C).
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9. Install Tooling (D).
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10. Install Tooling (E).
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11. Install Tooling (F).
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    Illustration 11	g01222900
    (1) Supply Oil

12. Connect hose assembly (1) from the pressurized flow meter to Tooling (D).

13. Connect a hose assembly from Tooling (E) to the No. 2 flow meter inlet for the cooler supply.

14. Connect a hose assembly from the No. 2 flow meter outlet to Tooling (F) for the lubrication supply oil.
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    Illustration 12	g01222914
    Speed Clutch "A"

15. Remove the plug and install Tooling (G).

    Note: If you are using individual pressure gauges to measure the pressures, refer to Table 3 for the correct pressure gauges.

16. Connect a pressure gauge to Tooling (G).
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    Illustration 13	g01222935
    Speed Clutch "C"

17. Remove the plug and install Tooling (H).

18. Connect a pressure gauge to Tooling (H).
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    Speed Clutch "B"

19. Remove the plug and install Tooling (U).

20. Connect a pressure gauge to Tooling (U).
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    Illustration 15	g01222937
    No. 3 Speed Clutch

21. Remove the plug and install Tooling (J).

22. Connect a pressure gauge to Tooling (J).
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    Illustration 16	g01222939
    No. 1 Speed Clutch

23. Remove the plug and install Tooling (K).

24. Connect a pressure gauge to Tooling (K).
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    Illustration 17	g01222940
    Direction Clutch "F1"

25. Remove the plug and install Tooling (L).

26. Connect a pressure gauge to Tooling (L).
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    Illustration 18	g01222942
    Direction Clutch "F2"

27. Remove the plug and install Tooling (M).

28. Connect a pressure gauge to Tooling (M).
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    Illustration 19	g01222943
    Reverse Direction Clutch

29. Remove the plug and install Tooling (N).

30. Connect a pressure gauge to Tooling (N).
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    Illustration 20	g01222944
    No. 2 Speed Clutch

31. Remove the plug and install Tooling (P).

32. Connect a pressure gauge to Tooling (P).
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    Illustration 21	g01222946
    Pump Pressure

33. Remove the plug and install Tooling (Q).

34. Connect a pressure gauge to Tooling (Q).

35. Connect a pressure gauge to Tooling (F) to measure the lubrication pressure.
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    Illustration 22	g01223031

36. Connect Tooling (R) to the clutch solenoids.
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    Illustration 23	g01223060
    Typical Example

37. Connect Tooling (R) to a suitable location.
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    Illustration 24	g01223230

38. Cover the rear of the transmission with a plastic sheet (2) to keep oil from spraying out.
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    Illustration 25	g01223065
    Tooling (R)

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    Illustration 26	g01457869
    Tooling (R)

39. Connect Tooling (R) to a power source. Refer to Tool Operating Manual, NEHS0644 or Tool Operating Manual, NEHS0996 for the correct operating instructions.

    Note: Make sure that the transmission is secured to the test bench. Tighten all bolts to the proper torque.

Test Procedure

TA3 Navigation

1. Select “Challenger Tractors”.

2. Select “35-12V”, “45-12V”, or “55-12V”.

Harness Test (TA3 only)

1. Make sure that the harness is properly connected.

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

3. Record the values in Table 5.

   Note: Do not continue testing until Harness Test passes.

Solenoid Test (TA2 only)

1. Make sure that the harness is properly connected.

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

3. Record the values in Table 5.

   Note: Do not continue testing until Solenoid Test passes.

Start Checks

Note: Refer to Testing and Adjusting, RENR1778, "Challenger 35, Challenger 45, and Challenger 55 Agricultural Tractors 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.

2. Adjust input flow to 76 ± 4 L/min (20 ± 1 US gpm).
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   Illustration 27	g02720621

   Note: .

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1000 ± 20 rpm.

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

5. Check for lockup or excessive drag in all ranges.

6. Stop the input rotation.

7. Stop the input flow.

Pump Pressure

1. Adjust input flow to 76 ± 4 L/min (20 ± 1 US gpm).

2. Adjust the input rotation to 1000 ± 20 rpm.

3. Shift the transmission to NEUTRAL.

4. The pump pressure must be 1758 ± 35 kPa (255 ± 5 psi).

5. Record the value in Table 6.

Lube Circuit

1. Adjust input flow to 114 ± 4 L/min (30 ± 1 US gpm).

2. Adjust the input rotation to 1000 ± 20 rpm.

3. Shift the transmission to NEUTRAL.

4. The pump pressure must be 1827 ± 104 kPa (265 ± 15 psi).

5. The lubrication inlet pressure must be 345 ± 70 kPa (50 ± 10 psi).

6. The lubrication outlet flow must be less than 11 L/min (3 US gpm).

   Note: The lubrication outlet flow is the difference between the cooler supply flow and lubrication supply oil.

7. Record the values in Table 7.

Proportional Valve Adjustment

1. Adjust input flow to 114 ± 4 L/min (30 ± 1 US gpm).

2. Adjust the input rotation to 1000 ± 20 rpm.

3. Shift the transmission to NEUTRAL.

4. Select "MC1", "MC2", "F1", and "F2" from the "SOL Test" menu on Tooling (R).

5. "F1" and "F2" should be 352 +28/-41 kPa (51 +4/-6 psi).

6. Record the values in Table 8.

Clutch Pressure

1. Adjust input flow to 114 ± 4 L/min (30 ± 1 US gpm).

2. Adjust the input rotation to 1000 ± 20 rpm.

3. Select "XMSN Test" on Tooling (R).

4. Shift the transmission through all ranges.

   Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.

5. All clutch pressures should be 1827 ± 103 kPa (265 ± 15 psi).

6. Record the values in Tables 11,12, and 13.

Clutch Fill Times

1. Adjust input flow to 114 ± 4 L/min (30 ± 1 US gpm).

2. Adjust the input rotation to 1000 ± 20 rpm.

3. Select "TURN ON ONE SOL" from the "SOL TEST" menu on Tooling (R).

4. Activate each solenoid.

5. Record the time for a rise in clutch pressure to stay above 1034 kPa (150 psi). The time must be between Time "A" and Time "B" on Table 14.

   Note: Time should be measured from solenoid actuation.

6. Record the values in Table 16.

7. Activate each solenoid.

8. Record the time for a rise in clutch pressure to stay above a value equivalent to a "steady-state" clutch pressure of 138 kPa (20 psi). The time must be between Time "A" and Time "B" on Table 15.

   Note: Time should be measured from solenoid actuation.

9. Record the values in Table 17.

10. All clutch pressure should be greater than 1758 ± 103.4 kPa (255 ± 15 psi).

11. Record the value in Table 18.

Proportional Valve Test

1. Adjust input flow to 114 ± 4 L/min (30 ± 1 US gpm).

2. Adjust the input rotation to 1000 ± 20 rpm.

3. Select "MC1/F1 RAMP TEST" from the "SOL TEST" menu on Tooling (R).

4. Actuate the "MC1/F1 RAMP TEST" and record the "F1" clutch pressure at the times in Table 20.

5. Repeat Steps 1,2,3, and 4 for "MC2/F2".

6. Record the values in Table 21.

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 22.

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

Transmission Bench Test Data Sheet

Solenoid Test

Pump Pressure Check

Lube Circuit Check

Proportional Valve Adjustment

Clutch Pressure Check

Clutch Fill Times

Proportional Valve Test

Contamination Control