- Oil/Gas Transmission:
- TH48-E80 (S/N: FRT1-UP)
Introduction
This Special Instruction provides the procedures and requirements for updating a standard eight speed oilfield transmission into a configuration having a stall mode. This mode engages 3 clutches within the planetary which stalls the torque converter. This will generate heat in order to speed up the warming of the power train during cold weather operation. This mode also performs the same function as PARK. This mode locks the output of the transmission from turning. Any transmissions that are updated in order to enable the warm up mode, will have both the NEUTRAL position and the PARK position. However, the 8F gear will no longer be available.
The following four top level arrangements can be upgraded:
The following procedures will be needed to be completed for this update:
- Replace the rotary selector spool assembly in the ICM controls with a new spool assembly.
- Verify the correct software version. Reflash the new software, if required. Then change the application code within the software.
- Reprogram the software in Caterpillar Electronic Technician and the OEM control system to enable the 2R gear selection.
- Install a dedicated switch and connect the switch in order to activate warm up mode.
Not all procedures that are listed above will be required on every unit. Use Table 1 as a guide in order to determine the procedures that must be performed. This determination should be based on the current configuration of the unit.
Procedures for Updating Transmission
| Item That Requires Updating | Current Status of Unit | Actions That Are Required |
|---|---|---|
| ICM Control Group | The control group contains 261-3384 Rotary Spool Assembly . | Replace the rotary selector spool assembly with 314-9928 Rotary Spool Assembly . |
| Software Version of Transmission | 320-7504 Power Train Software Gp or later version | Reset application code to 18001 |
| Any older software version | Reflash software to 320-7504 Power Train Software Gp or a newer version and set the application code to 18001. Update ET configurable parameters, as needed. See 3. | |
| Shift Controller | The rig utilizes J1939 based shift control. | Enable 2R on OEM control system or R plus the down arrow on the Caterpillar shifter, or install the dedicated warm up mode switch and connect the switch. |
| The rig utilizes SWG (pin-outs) for shift control. | Install the dedicated warm up mode switch and connect the switch. |
ReferenceSee Disassembly and Assembly, RENR9664, "TH48-E80 Oil/Gas Transmission"Parts Manual, SEBP4400, "TH48-E80 Oil/Gas Transmission"Special Instruction, REHS2818, "Application and Installation Guide for Petroleum Transmissions"
Use Table 2 below in order to locate the parts that are required for performing the update. Other parts such as O-ring seals may require replacement at the discretion of the installer. This should be based on the condition of the O-ring seal at disassembly. Refer to the parts manual in order to identify any such parts.
| Required Parts for the Update of the Transmission | ||
| Part Number | Description | Qty |
| 314-9928 317-0989 138-1645 8T-2925 320-7504 7G-6373 |
Rotary Spool Assembly Harness Assembly Spring Pin Spring Pin Power Train Software Gp Gasket |
1 1 1 1 1 1 |
Note: Not all parts that are listed will be used on every unit that is based on the setup of the unit prior to the update.
Replacement of ICM Rotary Selector Spool
- Remove the ICM control group from the transmission as shown in the Disassembly and Assembly, RENR9664, "Transmission Hydraulic Control-Remove".
- Once the valve group is removed from the transmission, disassemble the valve according to Disassembly and Assembly, "Transmission Hydraulic Control - Disassemble" to the point of the removal of the 261-3384 Rotary Spool Assembly .
- Replace this spool assembly with the 314-9928 Rotary Spool Assembly .
- Replace two spring pins 8T-2925 Spring Pin and 138-1645 Spring Pin with new parts in order to fasten the spool to the detent cam.
- Continue reassembling the valve group. Use the instructions in Disassembly and Assembly, "Transmission Hydrolic Control - Assemble".
- After assembly, the valve group should be reinstalled by following the instructions from the Disassembly and Assembly, "Transmission Hydrolic Control - Install" procedure.
Note: Upon completing the installation of 314-9928 Rotary Spool Assembly , the OEM has converted the 258-8741 Transmission Hydraulic Control Gp into a 314-9942 Transmission Hydraulic Control Gp . This part number should be used for any future service needs of the control group. It is recommended that the customer stamp the identification or etch the identification of this new part number in a noticeable location on the control group for future reference.
Update of the Transmission Software and Application Code
- Connect a PC to the transmission ECM by utilizing a communication adapter.
- Find the transmission ECM in Caterpillar Electronic Technician .
- Check the software part number. If the software is older than 320-7504 Power Train Software Gp , the ECM needs to be reflashed.
- Obtain a copy of 320-7504 Power Train Software Gp , or the latest version, in SIS Web. Flash the software onto the transmission ECM.
Note: Once the system has the updated software installed, configure only the parameters that are listed in Table 3. If the unit did not require reflashing of the software, it is still recommended that the parameters below be confirmed as correct for the unit that is being updated.
| Parameters for the TH48-E80 Oil/Gas Transmission | |||||||
|---|---|---|---|---|---|---|---|
| Top Level Arrangement | Description | Application Code (Standard) | Application Code (Warm Up Mode Installed) | Flywheel Teeth | Reference Torque (N·m)/(ft·lb) | System Battery Voltage | Shifter Input |
| 267-7506 | For use with CAT 3512 | 18000 | 18001 | Do Not Set | Do Not Set | 24V | "CAN" or "Switch to Ground" |
| 277-2235 | For use with CAT 3512 | 18000 | 18001 | Do Not Set | Do Not Set | 24V | "CAN" or "Switch to Ground" |
| 290-0059 | For use with QSK45 | 18000 | 18001 | 149 | 8541/6300 | 24V | "CAN" or "Switch to Ground" |
| 295-9193 | For use with QSK50 | 18000 | 18001 | 142 | 8832/6514 | 24V | "CAN" or "Switch to Ground" |
Finally, the application code must be changed on all units by removing 18000 and replacing the code with 18001.
Control Updates for Warm Up Mode Operation
A control interface will be needed for activating the warm up mode feature. This is the last task that is needed for updating the unit. There are two basic methods for completing this task. The method that is chosen will depend on the type of shifter. The OEM control system may utilize a J1939 based shifter. The OEM control system may utilize a SWG (pin out) shifter. The type of shifter that is utilized may also depend on the user's preference. Additional information on the basic set up of these control types can be found in Electrical Guide, REHS2818, "Application and Installation Guide (Electrical) for Petroleum Transmissions".
Procedure for Units That Utilize a J1939 Based Shifter
For this type of unit, warm up mode can be activated by programming the CAN shifter type in Caterpillar Electronic Technician. A J1939 TC1 command from the rig control system to the transmission that is requesting the 2R gear will engage warm up mode on the transmission if the conditions are correct to allow that shift. An alternative method would be to command 1R in order to engage PARK. Also, grounding the input for the warm up mode switch is an alternative method. The switch input is enabled by installing a dedicated switch between ECM Connector J1 (pin "64") and the sensor ground (pin "9") on the customer connector. This wiring may be installed directly into the ECM connector. Alternatively, the user may choose to replace 253-8395 OEM Harness As with replacement 317-0989 OEM Harness As . This switch can be wired between pin "4" and pin "9" on the customer connector after the new harness is installed. Refer to the ""Appendix A Warm Up Mode Control Logic" " for additional details on warm up mode activation criteria and additional details on when the warm up mode cannot be activated.
When the transmission software has the CAN shifter type enabled, modifications to the OEM controls will be required to command this gear. These modifications will vary by OEM. Consult the manufacture of the OEM control system for assistance on making this update.
Procedure for Units Utilizing and SWG (pin-out) Shifter
For units using this shifter type, warm up mode is enabled by installing a dedicated switch between ECM connector J1 pin "64" and the sensor ground pin "9" that are on the customer connector. This wiring may be installed directly into the ECM connector. The user may choose to replace 253-8395 OEM Harness As with replacement 317-0989 OEM Harness As . This switch can be wired between pin "4" and pin "9" on the customer connector once the new harness is installed.
When this circuit is closed, this circuit will activate warm up mode. Warm up mode will occur with the transmission in PARK, when the switch is activated, and the other required conditions are met. Please refer to ""Appendix A (Warm Up Mode Control Logic)" " for additional details on the logic that controls when warm up mode will engage and automatically disengage.
Appendix (Warm Up Mode Control Logic)
If 2R is commanded by the shifter, the warm up will engage if the following conditions are met:
- The transmission oil temperature is below 87 °C (189 °F).
- The torque converter oil temperature is below 110 °C (230 °F).
- The engine speed is less than 1000 rpm and more than 500 rpm.
The transmission will automatically shift to PARK if the following conditions are met:
- The transmission oil temperature exceeds 115 °C (239 °F).
- The engine speed exceeds 1300 rpm.
A "Transmission Abuse Warning Event" will be logged if engine speed exceeds 1000 rpm in PARK. A limit cycle timer will also make sure that the transmission warm up can only be engaged once every 60 seconds. Once the transmission oil cools or the transmission speed drops, warm up will again be automatically engage if the engagement criteria are met. Warm up will also be disengaged if there is an active ICM upshift/downshift solenoid diagnostic or an active short to battery diagnostic on the lockup clutch.
If warm up mode is engaged and the transmission output speed is more than 50 rpm, the transmission will do the following:
- The transmission will drop to PARK.
- The transmission will turn on the malfunction indicator lamp.
- The transmission will flag a 718-14 Transmission System Special Instruction message in Caterpillar Electronic Technician.
On J1939, the DM1 will indicate "lamp on".