Bench Test Procedure For A MT835, MT845, MT855, MT865, MTC835, MTC845, MTC855, and MTC865 Agricultural Tractor Transmission {3030, 3073} Caterpillar

Challenger

MT835 (S/N: BAM1-UP)

MT845 (S/N: BBP1-UP)

MT855 (S/N: BCC1-UP)

MT865 (S/N: BDS1-UP)

MTC835 (S/N: 8161-UP)

MTC845 (S/N: 8171-UP)

MTC855 (S/N: 8181-UP)

MTC865 (S/N: 8191-UP)

Introduction

© 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 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 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 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.

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Installation Procedure

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1. Install Tooling (A) on the rails of the test bench.
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2. Install Tooling (B).
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3. Install Tooling (C) to the rear of the transmission.
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4. Install Tooling (C) to the front of the transmission.
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5. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1625 kg (3582 lb).
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6. Install Tooling (D).
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7. Install Tooling (E) to both sides of the input end of the transmission.
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8. Install Tooling (E) to both sides of the output end of the transmission.
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9. Install Tooling (F).
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10. Install Tooling (G) to Tooling (F).
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11. Install Tooling (H) to Tooling (G).
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12. Install Tooling (J) to Tooling (H).
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13. Align the transmission with the input drive shaft.

14. Connect the input drive shaft to Tooling (J).
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15. Install the drive shaft guard.
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16. Tighten all four castle nuts and jack bolts.
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17. Install Tooling (K).
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18. Install Tooling (L).
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19. Install Tooling (M).
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20. Install Tooling (N).
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21. Install Tooling (P).
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22. Remove plug (1).
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23. Install Tooling (Q).
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24. Remove plug (2).
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25. Install Tooling (R).
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26. Install Tooling (S).
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27. Install Tooling (T).
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28. Install Tooling (U).
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29. Install Tooling (V).
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30. Connect hose assembly (3) from Tooling (V) to Tooling (T).
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    (4) Charge Pump Supply

31. Connect hose assembly (4) from the pressurized flow meter to Tooling (U).
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    (5) Cooler Inlet

32. Connect hose assembly (5) from Tooling (S) to the No. 2 flow meter inlet.
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    (6) Lubrication Oil Supply

33. Connect hose assembly (6) from the No. 2 flow meter outlet to Tooling (T).
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    (7) Charge Pressure

34. Connect a pressure gauge to pressure tap (7).
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    (8) Lubrication Bypass Pressure

35. Connect a pressure gauge to pressure tap (8).
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36. Connect a pressure gauge to pressure tap (9).
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    (10) Input Shaft Lubrication Pressure

37. Connect a pressure gauge to pressure tap (10).
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    (11) Reverse Shaft Lubrication Pressure

38. Connect a pressure gauge to pressure tap (11).
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    (12) Intermediate Shaft Pressure

39. Connect a pressure gauge to Tooling (12).
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    (13) Output Shaft Lubrication Pressure

40. Connect a pressure gauge to Tooling (13).
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    (14) Transmission Lubrication Pressure

41. Connect a pressure gauge to pressure tap (14).
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    Illustration 44	g06033090
    (23) No. 9 Clutch Control Pressure (20) No. 6 Clutch Control Pressure (15) No. 1 Clutch Control Pressure (16) No. 2 Clutch Control Pressure (17) No. 3 Clutch Control Pressure (18) No. 4 Clutch Control Pressure (19) No. 5 Clutch Control Pressure (21) No. 7 Clutch Control Pressure (22) No. 8 Clutch Control Pressure

42. Connect pressure gauges to the appropriate locations.
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43. Connect Tooling (W) to the appropriate location.
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44. Connect Tooling (W) to a suitable location.
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    Tooling (W)

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    Tooling (W)

45. Connect Tooling (W) to a power source. Refer to Tool Operating Manual, NEHS0644 orTool Operating Manual, NEHS0996 for the correct operating instructions.

Test Procedure

TA3 Navigation

1. Select “Challenger Tractors”.

2. Select “MT800-24V”.

Harness Test (TA3 only)

1. Make sure that the harness is properly connected.

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

3. Record the values in Table 6.

   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 (W) to perform the solenoid test.

3. Record the values in Table 6.

   Note: Do not continue testing until Solenoid 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 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.

2. Adjust the input flow to 146 L/min (39 US gpm).

3. The lubrication pressure must be 193 ± 69 kPa (28 ± 10 psi).

   Note: If there is no lube pressure after 3 seconds, stop input rotation and check connections on test bench and transmission.

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

5. Confirm the correct 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	Cl 8	Cl 9
   N								X
   F1	X				X
   F2		X			X
   F3			X		X
   F4				X	X
   R1					X				X
   R2						X			X
   R3							X		X
   R4								X	X

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

7. Verify all test points with the values in Table 7.

8. Record the values in Table 8.

   Note: Tooling (W) 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 to ensure the requirements of this procedure. Refer to Special Instruction, "Programming Features" for further Information.

9. Stop the input rotation.

High Idle Checks

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

1. Adjust the input flow to 146 L/min (39 US gpm).

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

3. Record the pressures for the active clutches in Table 10.

4. Record the values in Table 12 for charge pressure, cooler flow, lubrication pressure, clutch leakages, shaft pressures, and output speed.

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

5. Verify the test points with the values in Tables 9 and 11.

6. Shift the transmission through each FORWARD and REVERSE speed range. Repeat steps 1 through 6 for each gear range.

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

7. Adjust the input rotation to 1000 ± 10 rpm.

8. Stop the input rotation.

Lubrication Bypass Check

1. Adjust the input flow to 146 L/min (39 US gpm).

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

3. Slowly adjust the oil supply to 215 L/min (57 US gpm) at Tooling (V). At the same time, monitor the lubrication bypass pressure.

4. The lubrication bypass pressure should stabilize at 275 ± 34 kPa (40 ± 5 psi).

5. Record the values in table 14.

6. Stop the input rotation.

Cooler Bypass Check

1. Adjust the input flow to 146 L/min (39 US gpm).

2. Adjust Tooling (V) to provide 9 L/min (3 US gpm) flow to the lubrication supply.

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

4. Slowly increase the restriction at the No. 2 flow meter by adjusting the flow meter load valve clockwise until the cooler bypass pressure stabilizes.

5. The cooler bypass pressure should stabilize at 34 kPa (75 ± 5 psi).

6. Record the values in table 16.

7. Stop the input rotation.

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

Solenoid Test

Start Checks

Clutch Pressure Check

High Idle Check

Lubrication Bypass Check

Cooler Bypass Check

Contamination Control