- On Highway Transmission
- CX28 (S/N: T3X1-UP)
- Transmission
- CX28 (S/N: TBB1-UP)
Introduction
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
Machine Model | Transmission Arrangement |
CX28 |
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 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 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.
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. |
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. |
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.
Required Tools | |||
---|---|---|---|
Tool | Part Number | Part Description | Qty |
A | Link Bracket As | 4 | |
Bolt | 2 | ||
Washer | 2 | ||
8T-4779 | Bolt | 2 | |
8T-4122 | Washer | 2 | |
B | Spindle Adapter | 1 | |
8T-4186 | Bolt | 8 | |
8T-4121 | Washer | 8 | |
C | Adapter (Spindle Assembly) | 1 | |
D | Spindle Assembly | 1 | |
E | Nipple (Quick Disconnect) | 1 | |
Adapter | 1 | ||
F | Nipple | 2 | |
G | Elbow | 9 | |
Nipple | 9 | ||
H | Temperature Probe | 1 | |
9S-4181 | Plug(1) | 1 | |
J | Pressure Gauge (500 psi) | 10 | |
Pressure Gauge (60 psi) | 1 | ||
K | Isolation Pan | 1 | |
L | Adapter | 1 | |
M | Drive Adapter(2) | 1 | |
Drive Adapter(3) | 1 | ||
N | Ratcheting Turnbuckle | 3 | |
P | Adapter | 1 | |
Elbow (Swivel) | 1 | ||
R | 9U-5893 | Heat Exchanger | 1 |
S | Adapter | 1 | |
Adapter | 1 | ||
001-5258 | Elbow (Swivel) | 1 | |
T | Valve Pressure Regulator | 1 | |
Quick Disconnect Coupler | 4 | ||
Fitting As | 2 | ||
Pressure Gauge | 1 | ||
U | 4C-9913 | Flow Meter | 1 |
V | Transmission Analyzer Gp | 1 | |
Extension Cable | 1 | ||
Cable (Test) | 1 | ||
W | Portable Hydraulic Tester | 1 | |
X | Pressure Gauge ( |
9 | |
Quick Connect Coupler | 9 | ||
Y | Pressure Gauge ( |
3 | |
Quick Connect Coupler | 3 |
(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
- Install Tooling (A) to the input end of the transmission.
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Illustration 4 g01499053 - Install Tooling (A) to the output end of the transmission.
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Illustration 5 g01499373 - Remove Flywheel (1) and Adapter plate (2).
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Illustration 6 g01499413 - Install Tooling (B).
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Illustration 7 g01499513 - Install Tooling (C) to the transmission.
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Illustration 8 g01499753 - Install Tooling (D) to Tooling (C).
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Illustration 9 g01500093 - Tighten the collet on Tooling (D) to connect Tooling (D) to Tooling (B).
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Illustration 10 g01500393 - Remove plug (3) from the filter housing.
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Illustration 11 g01500473 - Install Tooling (E).
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Illustration 12 g01500753 - Remove plug (4).
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Illustration 13 g01500877 - Install Tooling (F).
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Illustration 14 g01501811 - Remove plug (5).
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Illustration 15 g01501841 - Install Tooling (F).
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Illustration 16 g01501856 - Remove plugs (6), (7), (8), (9), (10), (11), (12), (13) and (14).
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Illustration 17 g01501871 - Install Tooling (G) at every pressure port shown in Illustration 17.
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Illustration 18 g01501899 - Remove the drain plug from the left side of the transmission.
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Illustration 19 g01501906 - Install Tool assembly (H).
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Illustration 20 g01501968 (16) Main pressure - Install Pressure Gauge (16).
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Illustration 21 g01501985 (17) Lock Up Clutch pressure - Install Pressure Gauge (17).
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Illustration 22 g01501989 (18) Torque Converter Inlet Pressure - Install Pressure Gauge (18).
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Illustration 23 g01501991 (19) Cooler Inlet pressure
(20) Torque Converter Outlet pressure - Install Pressure Gauges (19) and (20).
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Illustration 24 g01501992 (21) Lubrication pressure - Install Pressure Gauge (21).
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Illustration 25 g01502023 (27) No. 1 Clutch - Install Pressure Gauge (22).
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Illustration 26 g01502265 (23) No. 2 Clutch
(24) No. 3 Clutch
(25) No. 4 Clutch - Install Pressure Gauge (23), (24), and (25).
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Illustration 27 g01502257 (26) No. 5 Clutch - Install Pressure Gauge (26).
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Illustration 28 g01502292 - Install Tooling (K) on the Test Bench.
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Illustration 29 g01502314 - Use a hoist to install the transmission on the test bench. The weight of the transmission is
363 kg (800 lb) .Show/hide tableIllustration 30 g01502315 - Install Tooling (L) on Tooling (D).
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Illustration 31 g01502327 - Install Tooling (M) on Tooling (L).
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Illustration 32 g01502329 - Install Drive shaft (27) on Tooling (M).
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Illustration 33 g01502332 - Install the Drive Shaft Guard (28).
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Illustration 34 g01502402 - Install Tooling (N) to the transmission to prevent movement of the transmission during the test.
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Illustration 35 g01502408 - Remove the plug and install Tooling (P) to the rear of the transmission.
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Illustration 36 g01502411 - Install Hose Assembly (29) to Tooling (P) and connect the Hose Assembly to the inlet side of Tooling (U).
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Illustration 37 g01502414 - Connect Hose Assembly (30) to the outlet side of Tooling (U) to the inlet of Tooling (R).
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Illustration 38 g01502422 - Connect Hose Assembly (31) to the outlet end of Tooling (R).
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Illustration 39 g01502450 - Remove the plug from the transmission and install Tooling (S).
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Illustration 40 g01502696 - Install the Hose assembly (31) from the outlet on Tooling (R) to Tooling (S).
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Illustration 41 g01502430 - Install Hose Assembly (32) to Tooling (E).
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Illustration 42 g01502432 - Install Tooling (T).
- Connect lube line (32) from Tooling (E) to Tooling (T).
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Illustration 43 g01502435 - Connect lube line (33) from Tooling (T) to Tooling (D). Adjust Tooling (T) to maintain a lubrication pressure of
70 kPa (10 psi) .Show/hide tableIllustration 44 g01502440 - Remove the wire harness (34) from the ECM.
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Illustration 45 g01502442 - Install Tooling (V) to wire harness (34).
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Illustration 46 g01457869 Tooling (V) - Connect Tooling (V) to a power source. Refer to the Tool operating manual NEHS0996 for the correct operating instructions.
- Fill the transmission with Dexron® IIIH oil. Refer to Operation and Maintenance Manual, SEBU8198, "CX28 Transmission" for the proper fill capacity.
Illustration 3 | g01498794 |
TA3 Navigation
- Select "OEM Transmissions".
- Select “CX28”.
Note: Choose appropriate voltage.
Harness Test (TA3 only)
- Make sure that the harness is properly connected.
- Use Tooling (V) to perform the harness test.
- Record the values in Table 6.
Note: Do not continue testing until Harness Test passes.
Start Checks
- 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.Show/hide tableIllustration 47 g02720621 - 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.
- Shift the transmission through all gears to eliminate air from the transmission controls.
- Verify that the active clutches are correct for each gear range. Refer to Table 4.
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Table 4 Clutch Engagement Check Gear Cl 1 Cl 2 Cl 3 Cl 4 Cl 5 L
U
CN 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 - Stop the input rotation.
Low Idle Checks
- Adjust the input rotation to 600 ± 20 rpm in the NEUTRAL position.
- Shift the transmission through each gear range.
- Record the values in Table 8 and Table 10 for each gear range.
- Verify all test points with the values in Table 7 and Table 9.
High Idle Checks
- 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.
- Shift the transmission through each gear range.
- Record the values in Table 12 and Table 14 for each gear range.
- Verify all test points with the values in Table 11 and Table 13.
Contamination Control
- Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.
- Record the results in Table 15.
- Remove the transmission from the test bench if the test bench oil supply is within specifications.
Transmission Bench Test Data Sheet
CATERPILLAR | Transmission Bench Test Data Sheet | Test Date:_______ |
Model:_______ | ||
Work Order:_______ | Serial No.:_______ |
Harness Test | Solenoid 1 | Solenoid 2 | Solenoid 3 | Solenoid 4 | Solenoid 5 | Solenoid 6 |
_______ Ohms |
_______ Ohms |
_______ Ohms |
_______ Ohms |
_______ Ohms |
_______ Ohms |
Low Idle Checks
Low Idle Checks | Input Speed (600 ± 20 rpm) | |||||||
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Gear | Cooler Flow | Lubrication Pressure | Main Relief Valve Pressure | Torque Converter Inlet Pressure | Lockup Clutch Pressure | Torque Converter Outlet Pressure | ||
R | ||||||||
N | |
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2 | |
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4 | |
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5 | |
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6 | |
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Low Idle Checks | Input Speed (600 ± 20 rpm) | |||||
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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) |
R | ||||||
N | ________ |
________ | ________ | ________ | ________ | |
1 | ________ |
________ | ________ | ________ | ________ | ________ |
2 | ________ |
________ | ________ | ________ | ________ | ________ |
3 | ________ |
________ | ________ | ________ | ________ | ________ |
4 | ________ |
________ | ________ | ________ | ________ | ________ |
5 | ________ |
________ | ________ | ________ | ________ | ________ |
6 | ________ |
________ | ________ | ________ | ________ | ________ |
Low Idle Pressure Checks | |||||||
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Gear | Active Clutches | Cl 1 | Cl 2 | Cl 3 | Cl 4 | Cl 5 | |
R | 3 | 5 | |||||
N | 5 | |
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1 | 1 | 5 | |
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2 | 1 | 4 | |
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3 | 1 | 3 | |
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4 | 1 | 2 | |
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5 | 2 | 3 | |
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6 | 2 | 4 | |
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Low Idle Pressure Checks | |||||||
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Gear | Active Clutches | Cl 1 | Cl 2 | Cl 3 | Cl 4 | Cl 5 | |
R | 3 | 5 | ___________ |
___________ |
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N | - | 5 | ___________ |
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1 | 1 | 5 | ___________ |
___________ |
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2 | 1 | 4 | ___________ |
___________ |
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3 | 1 | 3 | ___________ |
___________ |
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4 | 1 | 2 | ___________ |
___________ |
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5 | 2 | 3 | ___________ |
___________ |
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6 | 2 | 4 | ___________ |
___________ |
High Idle Checks
High Idle Checks | Input Speed (2100 ± 20 rpm)(1) | |||||
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Gear | Cooler Flow | Lubrication Pressure | Main Relief Valve Pressure | Torque Converter Inlet Pressure | Lockup Clutch Pressure | Torque Converter Outlet Pressure |
R(1) | |
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N(1) | |
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2 | |
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6 | |
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(1) | Shifting in and out of REVERSE must be done while the input speed is 1250 rpm. |
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) |
R | ________ |
________ | ________ | ________ | ________ | |
N | ________ |
________ | ________ | ________ | ________ | |
1 | ________ |
________ | ________ | ________ | ________ | |
2 | ________ |
________ | ________ | ________ | ________ | ________ |
3 | ________ |
________ | ________ | ________ | ________ | ________ |
4 | ________ |
________ | ________ | ________ | ________ | ________ |
5 | ________ |
________ | ________ | ________ | ________ | ________ |
6 | ________ |
________ | ________ | ________ | ________ | ________ |
High Idle Pressure Checks | |||||||
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Gear | Active Clutches | Cl 1 | Cl 2 | Cl 3 | Cl 4 | Cl 5 | |
R | 3 | 5 | |
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N | 5 | |
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1 | 1 | 5 | |
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2 | 1 | 4 | |
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3 | 1 | 3 | |
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4 | 1 | 2 | |
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5 | 2 | 3 | |
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6 | 2 | 4 | |
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High Idle Pressure Checks | |||||||
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Gear | Active Clutches | Cl 1 | Cl 2 | Cl 3 | Cl 4 | Cl 5 | |
R | 3 | 5 | ___________ |
___________ |
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N | - | 5 | ___________ |
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1 | 1 | 5 | ___________ |
___________ |
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2 | 1 | 4 | ___________ |
___________ |
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3 | 1 | 3 | ___________ |
___________ |
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4 | 1 | 2 | ___________ |
___________ |
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5 | 2 | 3 | ___________ |
___________ |
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6 | 2 | 4 | ___________ |
___________ |
Contamination Control
ISO Particle Count | Sample the test bench oil supply. *ISO 4406 is 16/13 or better |
________/________Particle Count |
______________________________________ Technician |
______________________________________ Supervisor |