- Transmission:
- TA19 (S/N: XAE1-UP; XAF1-UP)
Introduction
Revision     | Summary of Changes in REHS3622     |
02     | Updated arrangement numbers in Table 2. Updated Introduction. Added "Think Safety" graphic.     |
© 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.
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. 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 in order 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. In order to address an urgent need, use the following resources to communicate your request to Caterpillar Repair Process Engineering:
- Cat Dealer Techinical Communicator
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- Knowledge Network
Sales Model     | Transmission Arrangement     |
---|---|
TA19-4WD     | 317-5322 317-5323     |
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.
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 in order 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.
Illustration 1 | g02139237 |
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 in order to develop this test procedure.
Required Tools     | |||
---|---|---|---|
Tool     | Part Number     | Part Description     | Qty     |
A     | 1U-9584     | Rail As     | 2     |
1U-9585 | Block Gp Transmission Mounting Group     |
8     | |
B     | 138-7575     | Link Bracket     | 4     |
7X-2562 | Bolt (16x2x35)     | 4     | |
C     | 1U-9722     | Load Binder As (Ratchet Type)     |
2     |
D     | 4C-9032     | Plate Adapter     | 1     |
8T-3957 | M12x1.75x30mm     | 4     | |
E (1)     | 9W-1454     | Cover     | 1     |
6V-3966 | Nipple Assembly     | 1     | |
5P-3863 | O-Ring Seal     | 1     | |
F     | 7M-8485     | O-Ring Seal     | 1     |
5P-0492 | Adapter     | 1     | |
8C-9024 | Fitting As (PLAIN)     | 1     | |
G     | 6V-3965     | Fitting As (Quick Disconnect)     | 1     |
4J-0524 | O-Ring Seal     | 1     | |
H     | 277-2363     | Transmission Analyzer Tool Group     |
1     |
9U-7498 | Adapter Cable As (TRANSMISSION ANALYZER)     |
1     | |
9U-7496 | Cable (TEST)     | 1     | |
1U-9480 | Cable Adapter     | 9     | |
K     | 8T-0855     | Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))     | 10     |
8T-0862 | Pressure Gauge (−100 to 500 kPa (−15 to 72 psi))     | 6     | |
8T-0854 | Pressure Gauge (0 to 145 kPa (0 to 145.0 psi))     | 1     | |
6V-4144 | Coupler     | 17     | |
L     |     | O-Ring Seal     |     |
Threaded Flange     |     | ||
90 degree Nipple (Pipe)     |     | ||
Threaded Adapter     |     | ||
Quick Connect     |     |
( 1 ) | Refer to Illustration 1. |
Illustration 2 | g02709979 |
Installation Procedure
- Install Tooling (A) on the rails of the test bench, as shown.
Illustration 3 | g02711356 |
- Install tooling (B) to the front lift points.
Illustration 4 | g02711371 |
- Install tooling (B) to the rear lift points.
Illustration 5 | g02711411 |
Illustration 6 | g02711399 |
- Use a hoist to install the transmission on the test bench. The weight of the transmission is 1177 kg (2596.0 lb).
Illustration 7 | g02711420 |
- Install Tooling (C) to the front and rear of the transmission.
Illustration 8 | g02711424 |
- Install Tooling (D) to the yoke.
Illustration 9 | g02711438 |
- Align the transmission with the input drive shaft.
Illustration 10 | g02711479 |
- Connect the input drive shaft to Tooling (D) .
- Install the drive shaft guard.
Illustration 11 | g02711505 |
- Remove cover (1) and install Tooling (E) .
Illustration 12 | g02711512 |
Illustration 13 | g02711539 |
- Remove cover (2) and install Tooling (E) .
Illustration 14 | g02711563 |
Illustration 15 | g02711566 |
- Remove cover (3) and install Tooling (E) .
Illustration 16 | g02711573 |
Illustration 17 | g02711569 |
- Remove plugs (4), (5), and (6).
Illustration 18 | g02711598 |
- Install tooling (F) to three locations.
Illustration 19 | g02711620 |
- Connect hose assembly (7) from the pressurized flow meter to Tooling (F) .
Note: The flow meter will measure the flow of the supply oil.
Illustration 20 | g02711631 |
(7) Charge Pump Supply |
- Connect hose assembly (8) from the outlet of the No. 2 flow meter to Tooling (F) .
Illustration 21 | g02711695 |
(8) Lubrication Oil Supply |
- Connect hose assembly (9) from Tooling (F) to the inlet of the No. 2 flow meter.
Note: The No. 2 flow meter will measure oil returning to the test bench.
Illustration 22 | g02711728 |
(9) Lubrication Oil Supply |
- Remove dust cap from tap (10) and connect pressure gauge.
Illustration 23 | g02711756 |
(10) Pressure tap for Lubrication Inlet Oil Pressure |
- Remove plug (11) .
Illustration 24 | g02711929 |
- Install Tooling (G) .
Illustration 25 | g02711998 |
(12) Pressure Tap for Lubrication Out Oil Pressure |
- Connect a pressure gauge to pressure tap (12) .
- Remove dust cap from tap (13) and connect a pressure gauge.
Illustration 26 | g02712040 |
(13) Main Supply Pressure |
- Connect a pressure gauge to pressure tap (14) .
Illustration 27 | g02712066 |
(14) Output Shaft Lubrication Pressure |
- Connect a pressure gauge to pressure tap (15) .
Illustration 28 | g02712072 |
(15) Intermediate Shaft Lubrication Pressure |
- Connect a pressure gauge to pressure tap (16) .
Illustration 29 | g02712078 |
(16) Reverse Shaft Lubrication Pressure |
- Connect a pressure gauge to pressure tap (17) .
Illustration 30 | g02712169 |
(17) Lubrication In Pressure |
- Remove covers (18) and (19) .
Illustration 31 | g02712131 |
- Remove filter.
Illustration 32 | g02712159 |
- Install Tooling (L) which directs oil to the sump.
Illustration 33 | g02712225 |
- Remove dust caps and connect pressure gauges to pressure taps (20), (21), (22), (23), and (24) .
Illustration 34 | g02712182 |
(20) No. 1 Clutch Control Pressure (21) No. 2 Clutch Control Pressure (22) No. 3 Clutch Control Pressure (23) No. 4 Clutch Control Pressure (24) No. 9 Clutch Control Pressure |
- Remove dust caps and connect pressure gauges to pressure taps (25), (26), (27), and (28) .
Illustration 35 | g02712241 |
(25) No. 8 Clutch Control Pressure (26) No. 7 Clutch Control Pressure (27) No. 6 Clutch Control Pressure (28) No. 5 Clutch Control Pressure |
- Connect Tooling (H) to five clutch solenoids.
Illustration 36 | g02712244 |
- Connect Tooling (H) to four clutch solenoids.
Illustration 37 | g02712252 |
- Connect Tooling (H) to a suitable location.
Illustration 38 | g02712258 |
- Connect Tooling (H) to a power source. Refer to Tool Operating Manual, NEHS0996-00 for the correct operating instructions.
Illustration 39 | g02712702 |
Test Procedure
Solenoid Test
- Make sure that the Tooling (H) is properly connected to the transmission.
- Use Tooling (H) to perform the solenoid test.
- Record the values in Table 11.
Start Checks
- If you are using SAE 10W oil, warm the oil to 50 °C (125.0 °F). If you are using Mobil DTE11 oil, warm the oil to 34 °C (95.0 °F). Maintain this temperature for the duration of the test.
- Adjust the supply flow to 120 L/min (31.7 US gpm).
Illustration 40 | g02712705 |
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.
- The lubrication pressure must be minimum 137 kPa (20.0 psi).
- Shift the transmission through all speed ranges in order to eliminate air from the transmission controls.
- Verify that the active clutches are correct for each gear range. refer to Table 5.
- With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 rpm.
- Verify all test points with the values in Table 4.
- Record the values in table 12.
Note: Tooling (S) 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 in order to ensure the requirements of this procedure. Refer to Special Instruction, "Programming Features" for further Information.
- Stop the input rotation.
Start Checks     | ||||
---|---|---|---|---|
Pump Flow And Pressures     |
Input Speed (700 ± 10 rpm) Input Flow 120 L/min (31.7 US gpm)     |
|||
Gear     | Supply Flow     | Charge Pressure     | Cooler Flow     | Lubrication Pressure     |
FWD 1     | 157 L/min (41.5 US gpm)     |
2482 ± 34 kPa (360.0 ± 5.0 psi)     |
120 L/min (31.7 US gpm)     |
103 ± 69 kPa (15.0 ± 10.0 psi)     |
NEUTRAL     | 207 ± 83 kPa (30.0 ± 12.0 psi) |
Transmission Clutch Assignments     | |||||||||
---|---|---|---|---|---|---|---|---|---|
Operation     | Clutches     | ||||||||
1 | 2     | 3     | 4     | 5     | 6     | 7     | 8     | 9     | |
FWD 1     |
X     |     |     |     | X     |     |     |     |     |
FWD 2     |
    | X     |     |     | X     |     |     |     |     |
FWD 3     |
    |     | X     |     | X     |     |     |     |     |
FWD 4     |
    |     |     | X     | X     |     |     |     |     |
Neutral     |     |     |     |     |     |     |     | X     |     |
REV 1     |
    |     |     |     | X     |     |     |     | X     |
REV 2     |
    |     |     |     |     | X     |     |     | X     |
REV 3     |
    |     |     |     |     |     | X     |     | X     |
REV 4     |
    |     |     |     |     |     |     | X     | X     |
High Idle Checks
Note: Make all shifts from NEUTRAL at 1000 ± 10 rpm.
- Adjust the inlet flow to 120 L/min (31.7 US gpm).
- Adjust the input rotation to 2100 ± 10 rpm in the NEUTRAL position.
- Record the pressures for the active clutches in Table 13.
- Record the values in Table 13 for charge pressure, cooler flow, lubrication pressure, clutch leakages, shaft pressures, and output speed and 14 for clutch pressures.
Note: Calculate clutch leakage by subtracting cooler flow from supply flow.
- Verify the test points with the values in Tables 6 and 7.
- Shift the transmission through each FORWARD and REVERSE speed range. Repeat steps 1 through 5 for each gear range.
- Stop the input rotation.
Clutch Pressures     | |||||||||
---|---|---|---|---|---|---|---|---|---|
Gear     | Clutch 1     |
Clutch 2     |
Clutch 3     |
Clutch 4     |
Clutch 5     |
Clutch 6     |
Clutch 7     |
Clutch 8     |
Clutch 9     |
FWD 1     | 2482 ± 34 kPa (360.0 ± 5.0 psi)     |
    |     |     | 2482 ± 34 kPa (360.0 ± 5.0 psi)     |
    |     |     |     |
FWD 2     |     | 2482 ± 34 kPa (360.0 ± 5.0 psi)     |
    |     | 2482 ± 34 kPa (360.0 ± 5.0 psi)     |
    |     |     |     |
FWD 3     |     |     | 2482 ± 34 kPa (360.0 ± 5.0 psi)     |
    | 2482 ± 34 kPa (360.0 ± 5.0 psi)     |
    |     |     |     |
FWD 4     |     |     |     | 2482 ± 34 kPa (360.0 ± 5.0 psi)     |
2482 ± 34 kPa (360.0 ± 5.0 psi)     |
    |     |     |     |
N     |     |     |     |     |     |     |     | 2482 ± 34 kPa (360.0 ± 5.0 psi)     |
    |
REV 1     |     |     |     |     |     |     |     | 2482 ± 34 kPa (360.0 ± 5.0 psi)     |
2482 ± 34 kPa (360.0 ± 5.0 psi)     |
REV 2     |     |     |     |     |     |     | 2482 ± 34 kPa (360.0 ± 5.0 psi)     |
    | 2482 ± 34 kPa (360.0 ± 5.0 psi)     |
REV 3     |     |     |     |     |     | 2482 ± 34 kPa (360.0 ± 5.0 psi)     |
    |     | 2482 ± 34 kPa (360.0 ± 5.0 psi)     |
REV 4     |     |     |     |     | 2482 ± 34 kPa (360.0 ± 5.0 psi)     |
    |     |     | 2482 ± 34 kPa (360.0 ± 5.0 psi)     |
High Idle Checks     | Input Speed (2100 ± 10 rpm)     | |||||||
---|---|---|---|---|---|---|---|---|
Gear     | Supply Flow     | Charge Pressure kPa (psi)     |
Cooler Flow L/min (gpm)     |
Lubrication Pressure kPa (psi)     |
Leakage     | |||
FWD 1     | 120 L/min (31.7 US gpm)     |
2482 ± 34 kPa (360 ± 5 psi)     |
219 ± 19 L/min (31.7 ± 2.7 US gpm)     |
103 ± 69 kPa (15.0 ± 10.0 psi)     |
11 ± 3 L/min (3.0 ± 1.0 US gpm)     |
|||
FWD 2     | 103 ± 69 kPa (15.0 ± 10.0 psi) |
|||||||
FWD 3     | 103 ± 69 kPa (15.0 ± 10.0 psi) |
|||||||
FWD 4     | 103 ± 69 kPa (15.0 ± 10.0 psi) |
|||||||
N     | 193.0 ± 19.0 kPa (28.0 ± 2.8 psi) |
|||||||
REV 1     | 103 ± 69 kPa (15.0 ± 10.0 psi) |
|||||||
REV 2     | 103 ± 69 kPa (15.0 ± 10.0 psi) |
|||||||
REV 3     | 103 ± 69 kPa (15.0 ± 10.0 psi) |
|||||||
REV 4     | 103 ± 69 kPa (15.0 ± 10.0 psi) |
|||||||
Gear     | Input Shaft Lubrication kPa (psi)     |
Reverse Shaft Lubrication kPa (psi)     |
Intermediate Shaft Lubrication kPa (psi)     |
Output Shaft Lubrication kPa (psi)     |
    | |||
FWD 1     | 151 ± 27 kPa (22.0 ± 4.0 psi)     |
144 ± 27 kPa (21.0 ± 4.0 psi)     |
90 ± 27 kPa (13.0 ± 4.0 psi)     |
144 ± 27 kPa (21.0 ± 4.0 psi)     |
||||
FWD 2     | 151 ± 27 kPa (22.0 ± 4.0 psi)     |
151 ± 27 kPa (22.0 ± 4.0 psi)     |
103 ± 27 kPa (15.0 ± 4.0 psi)     |
144 ± 27 kPa (21.0 ± 4.0 psi)     |
||||
FWD 3     | 144 ± 27 kPa (21.0 ± 4.0 psi)     |
144 ± 27 kPa (21.0 ± 4.0 psi)     |
131 ± 27 kPa (19.0 ± 4.0 psi)     |
144 ± 27 kPa (21.0 ± 4.0 psi)     |
||||
FWD 4     | 151 ± 34 kPa (22.0 ± 5.0 psi)     |
144 ± 27 kPa (21.0 ± 4.0 psi)     |
138 ± 27 kPa (20.0 ± 4.0 psi)     |
144 ± 27 kPa (21.0 ± 4.0 psi)     |
||||
N     | 207 ± 69 kPa (30 ± 10 psi)     |
207 ± 69 kPa (30.0 ± 10.0 psi)     |
207 ± 69 kPa (30.0 ± 10.0 psi)     |
207 ± 69 kPa (30.0 ± 10.0 psi)     |
||||
REV 1     | 144 ± 27 kPa (21 ± 4 psi)     |
138 ± 27 kPa (20.0 ± 4.0 psi)     |
131 ± 27 kPa (19.0 ± 4.0 psi)     |
144 ± 27 kPa (21.0 ± 4.0 psi)     |
||||
REV 2     | 144 ± 27 kPa (21 ± 4 psi)     |
138 ± 27 kPa (20.0 ± 4.0 psi)     |
131 ± 27 kPa (19.0 ± 4.0 psi)     |
138 ± 27 kPa (20.0 ± 4.0 psi)     |
||||
REV 3     | 124 ± 27 kPa (18.0 ± 4.0 psi)     |
117 ± 21 kPa (17.0 ± 3.0 psi)     |
110 ± 21 kPa (16.0 ± 3.0 psi)     |
117 ± 21 kPa (17.0 ± 3.0 psi)     |
||||
REV 4     | 110 ± 21 kPa (16.0 ± 3.0 psi)     |
110 ± 21 kPa (16.0 ± 3.0 psi)     |
103 ± 21 kPa (15.0 ± 3.0 psi)     |
110 ± 21 kPa (16.0 ± 3.0 psi)     |
Lubrication Bypass Check
- Adjust the inlet flow to 120 L/min (31.7 US gpm).
- Adjust the input rotation to 2100 ± 10 rpm.
- Slowly adjust the oil supply to 215 L/min (57.0 US gpm) at tooling (R). At the same time monitor the lubrication bypass pressure.
- The lubrication bypass pressure should stabilize at 350 ± 34 kPa (50.8 ± 5.0 psi).
- Record the values in table 15.
- Stop the input rotation.
Lubrication Bypass     | |
---|---|
Lubrication Bypass Pressure     | 350 ± 34 kPa (50.8 ± 5.0 psi)     |
Cooler Bypass Check
- Adjust the inlet flow to 120 L/min (31.7 US gpm).
- Adjust pressurized flow meter in order to provide 9 L/min (2.5 US gpm) flow to the lubrication supply .
- Adjust the input rotation to 2100 ± 10 rpm.
- Slowly increase the restriction at the number 2 flow meter by adjusting the flow meter load valve clockwise until the cooler bypass pressure stabilizes.
- The cooler bypass pressure should Stabilize at 724 ± 34 kPa (105.0 ± 5.0 psi).
- Record the values in table 16.
- Stop the input rotation.
Cooler Bypass     | |
---|---|
Cooler Bypass Pressure     | 724 ± 34 kPa (105.0 ± 5.0 psi)     |
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 17.
- 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.:     |
Solenoid Test
Solenoid Test     | Solenoid 1     | Solenoid 2     | Solenoid 3     | Solenoid 4     | Solenoid 5     | Solenoid 6     | Solenoid 7     | Solenoid 8     | Solenoid 9     |
______ ohms |
______ ohms     |
______ ohms     |
______ ohms     |
______ ohms     |
______ ohms     |
______ ohms     |
______ ohms     |
______ ohms     |
Start Checks
Pump Flow And Pressures     |
Input Speed (700 ± 10 rpm) Input Flow (120 L/min)(31.7 US gpm)     |
|||
Oil Temperature     | °C (°F)     | |||
Gear     | Pump Flow     | Charge Pressure     | Lubrication Flow     | Lubrication Pressure     |
FORWARD 1     | ______________     |
______________     |
______________     |
______________     |
NEUTRAL     | ______________     |
______________     |
______________     |
______________     |
REVERSE 1     | ______________     |
______________     |
______________     |
______________     |
Clutch Pressures
Clutch Pressures     | |||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|
Gear     | Clutches     | Clutch 1     |
Clutch 2     |
Clutch 3     |
Clutch 4     |
Clutch 5     |
Clutch 6     |
Clutch 7     |
Clutch 8     |
Clutch 9     |
|
FWD 1     | 8     | 9     |     |     |     |     |     |     |     | _____     | _____     |
FWD 2     | 7     | 9     |     |     |     |     |     |     | _____     |     | _____     |
FWD 3     | 6     | 9     |     |     |     |     |     | _____     |     |     | _____     |
FWD 4     | 5     | 9     |     |     |     |     | _____     |     |     |     | _____     |
N     | -     | 8     |     |     |     |     |     |     |     | _____     |     |
REV 1     | 1     | 5     | _____     |     |     |     | _____     |     |     |     |     |
REV 2     | 2     | 5     |     | _____     |     |     | _____     |     |     |     |     |
REV 3     | 3     | 5     |     |     | _____     |     | _____     |     |     |     |     |
REV 4     | 4     | 5     |     |     |     | _____     | _____     |     |     |     |     |
High Idle Check
High Idle Checks     | Input Speed (2100 ± 10 rpm)     | ||||
---|---|---|---|---|---|
Gear     | Supply Flow     | Charge Pressure kPa (psi)     |
Cooler Flow L/min (gpm)     |
Lubrication Pressure kPa (psi)     |
Leakage     |
FWD 1     |     |     |     |     |     |
FWD 2     |     |     |     |     |     |
FWD 3     |     |     |     |     |     |
FWD 4     |     |     |     |     |     |
N     |     |     |     |     |     |
REV 1     |     |     |     |     |     |
REV 2     |     |     |     |     |     |
REV 3     |     |     |     |     |     |
REV 4     |     |     |     |     |     |
Gear     | Input Shaft Lubrication kPa (psi)     |
Reverse Shaft Lubrication kPa (psi)     |
Intermediate Shaft Lubrication kPa (psi)     |
Output Shaft Lubrication kPa (psi)     |
Output Speed     |
FWD 1     |     |     |     |     |     |
FWD 2     |     |     |     |     |     |
FWD 3     |     |     |     |     |     |
FWD 4     |     |     |     |     |     |
N     |     |     |     |     |     |
REV 1     |     |     |     |     |     |
REV 2     |     |     |     |     |     |
REV 3     |     |     |     |     |     |
REV 4     |     |     |     |     |     |
Lubrication Bypass Check
Lubrication Bypass Check 350 ± 34 kPa (50.8 ± 5 psi)     |
kPa (psi)     |
Cooler Bypass Check
Cooler Bypass Check 724 ± 34 kPa (105 ± 5 psi)     |
kPa (psi)     |
Contamination Control
Contamination Control     | Sample the test bench oil supply.     |
________/________Particle Count     |
______________________________________ Technician     |
______________________________________ Supervisor     |