Bench Test Procedure For A CX35 On-Highway Transmission and a CX35-P800 Petroleum Transmission {3030, 3073} Caterpillar

On-Highway Transmission

CX35 (S/N: W3X1-UP)

Petroleum Transmission

CX35-P800 (S/N: TRJ1-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 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:

• 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 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.

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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.

FT Drawings

Illustration 4	g06065692
FT-3057 (Part 1) (1) 030-7935 Connector (2) 124-2024 Permanent Coupling (3) 122-6901 Hydraulic Hose(–16 CAT 294 Hose 132.1 cm) (4) 8V-7764 O-Ring Adapter

Illustration 5	g06065706
FT-3057 (Part 2) (1) 030-7935 Connector (2) 124-2024 Permanent Coupling (3) 122-6901 Hydraulic Hose(–16 CAT 294 Hose 81.3 cm) (4) 8V-7764 O-Ring Adapter

Illustration 6	g06065714
FT-3057 (Part 3) (2) 124-2024 Permanent Coupling (3) 122-6901 Hydraulic Hose(–16 CAT 294 Hose 20.3 cm) (5) 4C-9913 Flow Meter Gp (6) 5P-4248 Port Connector

Installation Procedure

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1. Install Tooling (A) to the input end of the transmission.
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   Illustration 8	g02060059

2. Install Tooling (A) to the output end of the transmission.
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3. Install Tooling (B) on the test bench.
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4. Use a hoist to install the transmission on the test bench. The weight of the transmission is 646 kg (1425 lb).

   Note: The Petroleum transmission with integral pump drive weighs 746 kg (1650 lb).

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5. Use Tooling (C) to secure the transmission to Tooling (B).
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6. Remove flywheel (1).
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7. Install Tooling (D).
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8. Install Tooling (E).
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9. Install Tooling (F).
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10. Tighten the collet on Tooling (F) to connect Tooling (F) to Tooling (D).
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    Illustration 17	g01275693

11. Install Tooling (G).
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12. Install Tooling (H).

    Note: Tooling (H) will adapt to the small drive shaft. If the large drive shaft is being used, install Tooling (J) on Tooling (H).

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13. Align the transmission with the input drive shaft.

14. Connect the input drive shaft to Tooling (H).
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15. Install the drive shaft guard.
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16. Remove plug (2).
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    (K) Torque Converter Outlet

17. Connect Tooling (K) from the transmission to Tooling (L).
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18. Connect Tooling (M) from Tooling (L) to Tooling (N).
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19. Remove plug (3).
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    (P) Lubrication Inlet

20. Connect Tooling (P) from Tooling (N) to the transmission.
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21. Connect the water supply (4) to Tooling (N).
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22. Connect the water outlet (5) from Tooling (N) to a drain.
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23. Install Tooling (Q).
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    Oil Temperature Sensor

24. Install Tooling (R).
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25. Install Tooling (S).
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26. Install Tooling (T).
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27. Install Tooling (U).

28. Connect lube line (6) from Tooling (Q) to Tooling (U).
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    (7) Spindle Lubrication

29. Connect lube line (7) from Tooling (U) to Tooling (F). Adjust Tooling (U) to maintain a lubrication pressure of 276 kPa (40 psi).

    Note: Step 27, 28and 29 are not applicable to the Petroleum Transmission. Connect the lubrication line from the test bench when testing the Petroleum Transmission. Maintain 276 kPa (40 psi) lubrication pressure.

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    Illustration 34	g01279659
    (8) Main Relief Valve Pressure

30. Connect a pressure gauge to pressure tap (8).
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    Illustration 35	g01279671
    (9) Transmission Lubrication Pressure

31. Connect a pressure gauge to pressure tap (9).
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    Illustration 36	g01279685
    (10) Cooler Inlet Pressure

32. Connect a pressure gauge to pressure tap (10).
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    Illustration 37	g01279692
    (11) Torque Converter Outlet Pressure

33. Connect a pressure gauge to pressure tap (11).
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    Illustration 38	g01279698
    (12) Torque Converter Inlet Pressure

34. Connect pressure gauge (12) to Tooling (S).
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    Illustration 39	g02060067
    (13) Lockup Clutch Pressure (14) No. 1 Clutch Pressure (15) No. 2 Clutch Pressure (16) No. 3 Clutch Pressure (17) No. 4 Clutch Pressure (18) No. 5 Clutch Pressure (19) No. 6 Clutch Pressure

35. Connect pressure lines to the proper locations.
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    Illustration 40	g02060064

36. Connect Tooling (V).
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37. Connect Tooling (V) to a suitable location.
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    Tooling (V)

38. Connect Tooling (V) to a power source. Refer to Tool Operating Manual, NEHS0996 for the correct operating instructions.

39. Fill the transmission with oil to the correct operating level. The CX35 uses Dexron® IIIH oil. The CX35-P800 uses SAE 10W TDTO oil. Refer to Operation and Maintenance Manual, SEBU8203, "CX35 Transmission"or Operation and Maintenance Manual, SEBU8428, "CX35-P800 Transmission"for the proper fill capacity.

Test Procedure

TA3 Navigation

1. Select “OEM Transmissions”.

2. Select “CX35-12V” or “CX35-24V”.

Harness Test

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 or the TDTO oil to 50 °C (122 °F). Maintain this temperature for the duration of the test. Refer to Testing and Adjusting, KENR5256, "CX35 On-Highway Transmission" or Testing and Adjusting, KENR6988, "CX35-P800 Transmission"for additional information.
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   Illustration 43	g02720621

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. Verify that the lubrication pressure is present.

   Note: If there is no lube pressure after 30 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	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
   F7		X	X				X
   F8		X			X		X

6. 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.

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

3. Record the Cooler Flow, Lubrication Pressure, Main Relief Valve Pressure, Torque Converter Inlet Pressure, Lockup Clutch Pressure, and Torque Converter Outlet Pressure values in Table 8 for each gear range.

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

5. Record the Clutch Pressure values in Table 10 for each gear range.

6. Verify all test points with the values in Table 9.

High Idle Checks

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

   Note: Always return to low idle rpm before shifting between gears.

2. Shift the transmission through each gear range.

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

3. Record the Cooler Flow, Lubrication Pressure, Main Relief Valve Pressure, Torque Converter Inlet Pressure, Lockup Clutch Pressure, and Torque Converter Outlet Pressure values in Table 12 for each gear range.

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

5. Record the Clutch Pressure values in Table 14 for each gear range.

6. Verify all test points with the values in 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

Harness Test

Low Idle Checks

High Idle Checks

Contamination Control