Bench Test Procedure For A CX28 On-Highway Transmission {3030, 3073} Caterpillar


Bench Test Procedure For A CX28 On-Highway Transmission {3030, 3073}

Usage:

CX28 T3X
On Highway Transmission
CX28 (S/N: T3X1-UP)
Transmission
CX28 (S/N: TBB1-UP)

Introduction

Table 1
Summary of Changes in REHS3485 
03  Standardized. 
02  Updated Introduction.
Added Canceled Replaced Parts statement. 
01  Added additional serial number prefix and transmission arrangements. 

© 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 a specific transmission arrangement. 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 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:

  • Caterpillar Dealer Technical Communicator

  • Dealer Solution Network

  • Caterpillar Technical Representative

  • Knowledge Network

Table 2
Machine Model  Transmission Arrangement 
CX28  287-5738, 293-9098, 293-9099, 293-9100, 293-9101, 293-9102, 293-9103, 293-9104, 293-9105, 299-8030, 310-7363, 311-4896, 311-4897, 311-7633, 311-7634, 311-7635, 311-7636, 311-7637, 311-7638, 311-7641, 311-7642, 311-7644, 311-7645, 313-4913, 314-6892, 314-6893, 314-5060, 316-6061, 317-2113, 317-7568, 317-9068, 317-9069, 319-8144, 320-0922, 320-2950, 320-2958, 321-0054, 321-3032, 321-3502, 321-6409, 321-8029, 331-6371, 331-6372 

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 1g02139237

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.



Illustration 2g00008666

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 often used to compare values on portions of transmission tests. 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.

------ 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 to develop this test procedure.

Table 3
Required Tools 
Tool  Part Number  Part Description  Qty 
439-3940  Link Bracket As 
8T-4139 Bolt 
8T-4223 Washer 
8T-4779 Bolt 
8T-4122 Washer 
325-9487  Spindle Adapter 
8T-4186 Bolt 
8T-4121 Washer 
1U-6698  Adapter (Spindle Assembly) 
1U-5999  Spindle Assembly 
6V-3966  Nipple (Quick Disconnect) 
5P-2937 Adapter 
6V-3965  Nipple 
6V-8076  Elbow 
6V-3965 Nipple 
4C-6265  Temperature Probe 
9S-4181 Plug(1) 
4C-6818  Pressure Gauge (500 psi)  10 
4C-6916 Pressure Gauge (60 psi) 
296-3645  Isolation Pan 
1U-6721  Adapter 
1U-9359  Drive Adapter(2) 
1U-9131 Drive Adapter(3) 
1U-9722  Ratcheting Turnbuckle 
6V-5258  Adapter 
001-5262 Elbow (Swivel) 
9U-5893  Heat Exchanger 
6V-5258  Adapter 
8C-3051 Adapter 
001-5258 Elbow (Swivel) 
1U-6392  Valve Pressure Regulator 
6V-3965 Quick Disconnect Coupler 
6V-3966 Fitting As 
8T-0856 Pressure Gauge 
4C-9913  Flow Meter 
277-2362  Transmission Analyzer Gp 
306-0397 Extension Cable 
311-4929 Cable (Test) 
4C-9910  Portable Hydraulic Tester 
8T-0855  Pressure Gauge ( 0 - 4000 kPa (0 - 580 psi)
6V-4144 Quick Connect Coupler 
8T-0854  Pressure Gauge ( 0 - 965 kPa (0 - 140 psi)
6V-4144 Quick Connect Coupler 
(1) Drill and tap this plug for the Temperature Probe.
(2) This adapter is used with the small drive shaft.
(3) This adapter is used with the large drive shaft.

Installation Procedure



    Illustration 3g01498794

  1. Install Tooling (A) to the input end of the transmission.


    Illustration 4g01499053

  2. Install Tooling (A) to the output end of the transmission.


    Illustration 5g01499373

  3. Remove Flywheel (1) and Adapter plate (2).


    Illustration 6g01499413

  4. Install Tooling (B).


    Illustration 7g01499513

  5. Install Tooling (C) to the transmission.


    Illustration 8g01499753

  6. Install Tooling (D) to Tooling (C).


    Illustration 9g01500093

  7. Tighten the collet on Tooling (D) to connect Tooling (D) to Tooling (B).


    Illustration 10g01500393

  8. Remove plug (3) from the filter housing.


    Illustration 11g01500473

  9. Install Tooling (E).


    Illustration 12g01500753

  10. Remove plug (4).


    Illustration 13g01500877

  11. Install Tooling (F).


    Illustration 14g01501811

  12. Remove plug (5).


    Illustration 15g01501841

  13. Install Tooling (F).


    Illustration 16g01501856

  14. Remove plugs (6), (7), (8), (9), (10), (11), (12), (13) and (14).


    Illustration 17g01501871

  15. Install Tooling (G) at every pressure port shown in Illustration 17.


    Illustration 18g01501899

  16. Remove the drain plug from the left side of the transmission.


    Illustration 19g01501906

  17. Install Tool assembly (H).


    Illustration 20g01501968
    (16) Main pressure

  18. Install Pressure Gauge (16).


    Illustration 21g01501985
    (17) Lock Up Clutch pressure

  19. Install Pressure Gauge (17).


    Illustration 22g01501989
    (18) Torque Converter Inlet Pressure

  20. Install Pressure Gauge (18).


    Illustration 23g01501991
    (19) Cooler Inlet pressure
    (20) Torque Converter Outlet pressure

  21. Install Pressure Gauges (19) and (20).


    Illustration 24g01501992
    (21) Lubrication pressure

  22. Install Pressure Gauge (21).


    Illustration 25g01502023
    (27) No. 1 Clutch

  23. Install Pressure Gauge (22).


    Illustration 26g01502265
    (23) No. 2 Clutch
    (24) No. 3 Clutch
    (25) No. 4 Clutch

  24. Install Pressure Gauge (23), (24), and (25).


    Illustration 27g01502257
    (26) No. 5 Clutch

  25. Install Pressure Gauge (26).


    Illustration 28g01502292

  26. Install Tooling (K) on the Test Bench.


    Illustration 29g01502314

  27. Use a hoist to install the transmission on the test bench. The weight of the transmission is 363 kg (800 lb).


    Illustration 30g01502315

  28. Install Tooling (L) on Tooling (D).


    Illustration 31g01502327

  29. Install Tooling (M) on Tooling (L).


    Illustration 32g01502329

  30. Install Drive shaft (27) on Tooling (M).


    Illustration 33g01502332

  31. Install the Drive Shaft Guard (28).


    Illustration 34g01502402

  32. Install Tooling (N) to the transmission to prevent movement of the transmission during the test.


    Illustration 35g01502408

  33. Remove the plug and install Tooling (P) to the rear of the transmission.


    Illustration 36g01502411

  34. Install Hose Assembly (29) to Tooling (P) and connect the Hose Assembly to the inlet side of Tooling (U).


    Illustration 37g01502414

  35. Connect Hose Assembly (30) to the outlet side of Tooling (U) to the inlet of Tooling (R).


    Illustration 38g01502422

  36. Connect Hose Assembly (31) to the outlet end of Tooling (R).


    Illustration 39g01502450

  37. Remove the plug from the transmission and install Tooling (S).


    Illustration 40g01502696

  38. Install the Hose assembly (31) from the outlet on Tooling (R) to Tooling (S).


    Illustration 41g01502430

  39. Install Hose Assembly (32) to Tooling (E).


    Illustration 42g01502432

  40. Install Tooling (T).

  41. Connect lube line (32) from Tooling (E) to Tooling (T).


    Illustration 43g01502435

  42. Connect lube line (33) from Tooling (T) to Tooling (D). Adjust Tooling (T) to maintain a lubrication pressure of 70 kPa (10 psi).


    Illustration 44g01502440

  43. Remove the wire harness (34) from the ECM.


    Illustration 45g01502442

  44. Install Tooling (V) to wire harness (34).


    Illustration 46g01457869
    Tooling (V)

  45. Connect Tooling (V) to a power source. Refer to the Tool operating manual NEHS0996 for the correct operating instructions.

  46. Fill the transmission with Dexron® IIIH oil. Refer to Operation and Maintenance Manual, SEBU8198, "CX28 Transmission" for the proper fill capacity.

Test Procedure

TA3 Navigation

  1. Select "OEM Transmissions".

  2. Select “CX28”.

    Note: Choose appropriate voltage.

Harness Test (TA3 only)

  1. Make sure that the harness is properly connected.

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

  3. Record the values in Table 6.

    Note: Do not continue testing until Harness Test passes.

Start Checks

  1. Warm the Dexron® IIIH oil to 50 °C (122 °F). Maintain this temperature for the duration of the test. Refer to Testing and Adjusting, KENR5107, "CX28 On-Highway Transmisson" for additional information.


    Illustration 47g02720621

  2. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 600 ± 20 rpm.

    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.

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

  4. Verify that the active clutches are correct for each gear range. Refer to Table 4.

    Table 4
    Clutch Engagement Check 
    Gear  Cl 1  Cl 2  Cl 3  Cl 4  Cl 5  L
    U
    C
     
    N          X   
    R      X    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 

  5. Stop the input rotation.

Low Idle Checks

  1. Adjust the input rotation to 600 ± 20 rpm in the NEUTRAL position.

  2. Shift the transmission through each gear range.

  3. Record the values in Table 8 and Table 10 for each gear range.

  4. Verify all test points with the values in Table 7 and Table 9.

High Idle Checks

  1. Adjust the input rotation to 2100 ± 20 rpm in the NEUTRAL position.

    Note: Shifting in and out of REVERSE must be done while the input speed is 1250 rpm.

  2. Shift the transmission through each gear range.

  3. Record the values in Table 12 and Table 14 for each gear range.

  4. Verify all test points with the values in Table 11 and Table 13.

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 15.

  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.:_______ 

Table 6
Harness Test  Solenoid 1  Solenoid 2  Solenoid 3  Solenoid 4  Solenoid 5  Solenoid 6 
_______
Ohms
_______
Ohms 
_______
Ohms 
_______
Ohms 
_______
Ohms 
_______
Ohms 

Low Idle Checks

Table 7
Low Idle Checks  Input Speed (600 ± 20 rpm) 
Gear  Cooler Flow  Lubrication Pressure  Main Relief Valve Pressure  Torque Converter Inlet Pressure  Lockup Clutch Pressure  Torque Converter Outlet Pressure 
             
R             
N  24 ± 4 L/min (6 ± 1 US gpm)  28 ± 14 kPa (4 ± 2 psi)  1931 ± 69 kPa (280 ± 10 psi)  331 ± 34 kPa (48 ± 5 psi)    290 ± 34 kPa (42 ± 5 psi) 
1  19 ± 4 L/min (5 ± 1 US gpm)  331 ± 34 kPa (48 ± 5 psi) 1696 ± 103 kPa (246 ± 15 psi) 
2  19 ± 4 L/min (5 ± 1 US gpm)  331 ± 34 kPa (48 ± 5 psi)
3  19 ± 4 L/min (5 ± 1 US gpm)  331 ± 34 kPa (48 ± 5 psi)
4  19 ± 4 L/min (5 ± 1 US gpm)  331 ± 34 kPa (48 ± 5 psi)
5  19 ± 4 L/min (5 ± 1 US gpm)  331 ± 34 kPa (48 ± 5 psi)
6  19 ± 4 L/min (5 ± 1 US gpm)  331 ± 34 kPa (48 ± 5 psi)

Table 8
Low Idle Checks  Input Speed (600 ± 20 rpm) 
Gear  Cooler Flow

L/min (gpm) 
Lubrication Pressure

kPa (psi) 
Main Relief Valve Pressure

kPa (psi) 
Torque Converter Inlet Pressure

kPa (psi) 
Lockup Clutch Pressure

kPa (psi) 
Torque Converter Outlet Pressure

kPa (psi) 
           

________ 
________  ________  ________    ________ 

________ 
________  ________  ________  ________  ________ 

________ 
________  ________  ________  ________  ________ 

________ 
________  ________  ________  ________  ________ 

________ 
________  ________  ________  ________  ________ 

________ 
________  ________  ________  ________  ________ 

________ 
________  ________  ________  ________  ________ 

Table 9
Low Idle Pressure Checks 
Gear  Active Clutches  Cl 1  Cl 2  Cl 3  Cl 4  Cl 5 
R  3  5           
N    5          1758 ± 138 kPa (255 ± 20 psi) 
1  1  5  1655 ± 138 kPa (240 ± 20 psi)        1758 ± 138 kPa (255 ± 20 psi) 
2  1  4  1655 ± 138 kPa (240 ± 20 psi)      1724 ± 138 kPa (250 ± 20 psi)   
3  1  3  1655 ± 138 kPa (240 ± 20 psi)    1724 ± 138 kPa (250 ± 20 psi)     
4  1  2  1724 ± 138 kPa (250 ± 20 psi)  1724 ± 138 kPa (250 ± 20 psi)       
5  2  3    1655 ± 138 kPa (240 ± 20 psi)  1793 ± 138 kPa (260 ± 20 psi)     
6  2  4    1655 ± 138 kPa (240 ± 20 psi)    1724 ± 138 kPa (250 ± 20 psi)   

Table 10
Low Idle Pressure Checks 
Gear  Active Clutches  Cl 1  Cl 2  Cl 3  Cl 4  Cl 5 
   
___________ 
 
___________ 
       
___________ 

___________ 
     
___________ 

___________ 
   
___________ 
 

___________ 
 
___________ 
   

___________ 

___________ 
     
 
___________ 

___________ 
   
 
___________ 
 
___________ 
 

High Idle Checks

Table 11
High Idle Checks  Input Speed (2100 ± 20 rpm)(1) 
Gear  Cooler Flow  Lubrication Pressure  Main Relief Valve Pressure  Torque Converter Inlet Pressure  Lockup Clutch Pressure  Torque Converter Outlet Pressure 
R(1)  45 ± 8 L/min (12 ± 2 US gpm)  152 ± 34 kPa (22 ± 5 psi)  2069 ± 138 kPa (300 ± 20 psi)  448 ± 34 kPa (65 ± 5 psi)    276 ± 35 kPa (40 ± 5 psi) 
N(1)  45 ± 8 L/min (12 ± 2 US gpm)  152 ± 34 kPa (22 ± 5 psi)  2137 ± 138 kPa (310 ± 20 psi)  448 ± 34 kPa (65 ± 5 psi)    276 ± 35 kPa (40 ± 5 psi) 
1  83 ± 12 L/min (22 ± 3 US gpm)  207 ± 34 kPa (30 ± 5 psi)  827 ± 69 kPa (120 ± 10 psi)   552 ± 35 kPa (80 ± 5 psi) 
2  83 ± 12 L/min (22 ± 3 US gpm)  207 ± 34 kPa (30 ± 5 psi)  827 ± 69 kPa (120 ± 10 psi) 1999 ± 69 kPa (290 ± 10 psi)  552 ± 35 kPa (80 ± 5 psi) 
3  83 ± 12 L/min (22 ± 3 US gpm)  207 ± 34 kPa (30 ± 5 psi)  827 ± 69 kPa (120 ± 10 psi) 552 ± 35 kPa (80 ± 5 psi)
4  83 ± 12 L/min (22 ± 3 US gpm)  207 ± 34 kPa (30 ± 5 psi)  827 ± 69 kPa (120 ± 10 psi) 448 ± 35 kPa (65 ± 5 psi)
5  83 ± 12 L/min (22 ± 3 US gpm)  207 ± 34 kPa (30 ± 5 psi)  827 ± 69 kPa (120 ± 10 psi) 448 ± 35 kPa (65 ± 5 psi)
6  83 ± 12 L/min (22 ± 3 US gpm)  207 ± 34 kPa (30 ± 5 psi)  827 ± 69 kPa (120 ± 10 psi) 448 ± 35 kPa (65 ± 5 psi)
(1) Shifting in and out of REVERSE must be done while the input speed is 1250 rpm.

Table 12
High Idle Checks  Input Speed (2100 ± 20 rpm) 
Gear  Cooler Flow

L/min (gpm) 
Lubrication Pressure

kPa (psi) 
Main Relief Valve Pressure

kPa (psi) 
Torque Converter Inlet Pressure

kPa (psi) 
Lockup Clutch Pressure

kPa (psi) 
Torque Converter Outlet Pressure

kPa (psi) 

________ 
________  ________  ________    ________ 

________ 
________  ________  ________    ________ 

________ 
________  ________  ________    ________ 

________ 
________  ________  ________  ________  ________ 

________ 
________  ________  ________  ________  ________ 

________ 
________  ________  ________  ________  ________ 

________ 
________  ________  ________  ________  ________ 

________ 
________  ________  ________  ________  ________ 

Table 13
High Idle Pressure Checks 
Gear  Active Clutches  Cl 1  Cl 2  Cl 3  Cl 4  Cl 5 
R  3  5      2068 ± 138 kPa (300 ± 20 psi)    2068 ± 138 kPa (300 ± 20 psi) 
N    5          2068 ± 138 kPa (300 ± 20 psi) 
1  1  5  1862 ± 103 kPa (270 ± 15 psi)        1965 ± 103 kPa (285 ± 15 psi) 
2  1  4  1862 ± 103 kPa (270 ± 15 psi)      1965 ± 103 kPa (285 ± 15 psi)   
3  1  3  1862 ± 103 kPa (270 ± 15 psi)    1965 ± 103 kPa (285 ± 15 psi)     
4  1  2  1965 ± 103 kPa (285 ± 15 psi)  1965 ± 103 kPa (285 ± 15 psi)       
5  2  3    1965 ± 103 kPa (285 ± 15 psi)  1965 ± 103 kPa (285 ± 15 psi)     
6  2  4    1896 ± 103 kPa (275 ± 15 psi)    1965 ± 103 kPa (285 ± 15 psi)   

Table 14
High Idle Pressure Checks 
Gear  Active Clutches  Cl 1  Cl 2  Cl 3  Cl 4  Cl 5 
   
___________ 
 
___________ 
       
___________ 

___________ 
     
___________ 

___________ 
   
___________ 
 

___________ 
 
___________ 
   

___________ 

___________ 
     
 
___________ 

___________ 
   
 
___________ 
 
___________ 
 

Contamination Control

Table 15
ISO Particle Count  Sample the test bench oil supply.
*ISO 4406 is 16/13 or better 
________/________Particle Count 

Table 16






______________________________________
Technician
 






______________________________________
Supervisor
 

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