Bench Test Procedure for a D6N Track-Type Tractor Transmission with Differential Steering {3030, 3073, 3139} Caterpillar

Track-Type Tractor

D6N (S/N: DJA1-UP; JAH1-UP; CCK1-UP; CBL1-UP; AKM1-UP; LJR1-UP; CCS1-UP; GHS1-UP; MLW1-UP; ALY1-UP; DJY1-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 technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

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.

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 used 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.

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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

Installation Procedure

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1. Install Tooling (A) to the input end of the transmission.
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2. Install Tooling (A) to the rear of the transmission.
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3. Use a hoist to install the transmission on the test bench. The weight of the transmission is 492 kg (1085 lb).
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4. Install Tooling (B) on the input shaft.
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5. Install Tooling (C) on Tooling (B).
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6. Install Tooling (D) on Tooling (C).
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7. Install Tooling (E) on Tooling (D).
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8. Align the transmission to the input drive shaft.

9. Connect the input drive shaft to Tooling (E).
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10. Install the drive shaft guard.
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11. Tighten all four castle nuts and jack bolts.
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12. Install Tooling (F).

    Note: Install the longest bolt in the lower hole location. Use the lower bolt to attach Tooling (G).

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13. Install Tooling (G) to the rear of the transmission to prevent movement during testing.
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14. Install Tooling (G) to the input end of the transmission to prevent movement during testing.
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15. Install Tooling (H) on the transmission case.
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16. Remove plug (1).
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17. Install Tooling (J).

18. Remove two plugs (2).
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19. Install Tooling (K).
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20. Connect hose assembly (3) from the pressurized flow meter to Tooling (F).

    Note: The flow meter will measure the flow of the supply oil.

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21. Connect hose assembly (4) from Tooling (J) to No. 2 flow meter inlet.

    Note: The No. 2 flow meter will measure the oil flow that is returning to the test bench.

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    Illustration 22	g00891034

22. Connect hose assembly (5) from the No. 2 flow meter to Tooling (H).
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    Illustration 23	g00891036
    (6) Main Supply Pressure (7) Transmission lubrication Pressure

    Note: If you are using individual pressure gauges to measure the pressures, refer to Table 3 for the correct pressure gauges.

23. Connect pressure gauge (6) to Tooling (K).

24. Connect pressure gauge (7) to Tooling (K).
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    Illustration 24	g03863982

25. Connect Tooling (L) to the transmission.
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    Illustration 25	g01905093
    Ground Clamp

26. Connect Tooling (L) to a suitable location.
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    Illustration 26	g00877509

27. Cover the transmission. Use a suitable clean cover.
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    Illustration 27	g00877510
    Tooling (L)

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    Tooling (L)

28. Connect Tooling (L) to a power source. Refer to Tool Operating Manual, NEHS0644 or Tool Operating Manual, NEHS0996 for the correct operating instructions.

    Note: Make sure that the transmission is secured to the test bench. Tighten all bolts to the proper torque.

Test Procedure

TA3 Navigation

1. Select “Dozers”.

2. Select “D6N-24V”.

Harness Test (TA3 Only)

1. Make sure that the harness is properly connected.

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

3. Record the values in Table 6.

   Note: Do not continue testing until Harness Test passes.

Solenoid Test (TA2 Only)

1. Make sure that the harness is properly connected.

2. Use Tooling (L) to perform the solenoid test.

3. Record the values in Table 6.

Note: Do not continue testing until Solenoid Test passes.

Start Checks

Note: Refer to Systems Operation, Testing and Adjusting, RENR5255, "D6N Track-Type Tractor Power Train" for the correct adjusting procedures.

1. If you are using SAE 10W oil, warm the oil to 50 °C (125 °F). If you are using Mobil DTE11 oil, warm the oil to 34 °C (95 °F). Maintain this temperature for the duration of the test.

2. Adjust the input flow to 38 ± 4 L/min (10 ± 1 US gpm).

3. Check the supply pressure. The correct supply pressure is 3000 ± 70 kPa (435 ± 10 psi).
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   Illustration 29	g02720621

4. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 500 ± 30 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.

5. Shift the transmission through all directions and through all speed ranges to eliminate air from the transmission controls.

6. 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
   N			X
   F1		X			X
   F2		X		X
   F3		X	X
   R1	X				X
   R2	X			X
   R3	X		X

7. Shift the transmission until all clutch fills are consistent.

8. The lubrication pressure must be 55 ± 14 kPa (8 ± 2 psi).

   Note: If there is no lube pressure after 3 seconds, stop input rotation and check connections on test bench and transmission.

9. Record the value in Table 7.

Clutch Leakage Check

1. Adjust the input flow to 75 ± 4 L/min (20 ± 1 US gpm). Maintain this flow during this check.

2. Adjust the input rotation to 2200 ± 30 rpm in the NEUTRAL position.

3. The lubrication pressure must be 214 ± 14 kPa (31 ± 2 psi) to continue.

4. Check the supply pressure. The correct supply pressure is 3100 ± 205 kPa (450 ± 30 psi).

5. Adjust the input rotation to 500 ± 30 rpm.

6. Shift the transmission to FORWARD 1.

7. Adjust the input rotation to 2200 ± 30 rpm.

8. Record the input flow in Table 8.

9. Record the output flow in Table 8.

10. The leakage is obtained by subtracting the output flow from the input flow.

11. Record the calculation in Table 8.

12. Adjust the input rotation to 500 ± 30 rpm.

13. Shift the transmission through positions FORWARD 2, FORWARD 3, REVERSE 1, REVERSE 2, REVERSE 3, and NEUTRAL. Repeat Steps 7 through 12 for each gear range.

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

14. The difference in leakage between SECOND gear and THIRD gear or between FORWARD and REVERSE should not exceed 2.3 L/min (0.6 US gpm).

15. The difference in leakage between FIRST gear and all other gears must not exceed 6.8 ± 3 L/min (1.8 ± 0.8 US gpm) of the average for this arrangement.

Lube Circuit Check

1. Adjust the input flow until the lube flow is 76 ± 4 L/min (20 ± 1 US gpm).

2. Adjust the input rotation to 500 ± 30 rpm.

3. Shift the transmission to FORWARD 2.

4. Adjust the input rotation to 2200 ± 30 rpm.

5. The lubrication pressure must be between 9 kPa (1 psi) of the average for this transmission arrangement. Reference is 207 ± 21 kPa (30 ± 3 psi).

6. Record the value in Table 9.

Speed Sensor Test

Note: These transmission arrangements have four speed sensors that must be tested. There are two intermediate speed sensors and two output speed sensors. Identify each speed sensor.

1. Adjust the input flow to 38 ± 4 L/min (10 ± 1 US gpm).

2. Adjust the input rotation to 500 ± 5 rpm.

3. Shift the transmission to FORWARD 1.

4. Adjust the input rotation to 800 ± 5 rpm.
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   Illustration 30	g01905114

5. Use Tooling (M) to measure the sensor signal voltage. Measure each speed sensor.

6. Record the values in Table 11.

7. Verify the test points with the values in Table 10.

8. Adjust the input rotation to 500 ± 5 rpm.

9. Shift the transmission to FORWARD 2.

10. Use Tooling (M) to measure the sensor signal voltage. Measure each speed sensor.

11. The value for the intermediate speed sensor should be approximately zero.

12. Verify that both output speed sensors continue to have output.

13. Record the values in Table 11.

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 12.

3. Remove the transmission from the test bench if the test bench oil supply is within specifications.

Transmission Bench Test Data Sheet

Solenoid Test

Start Checks

Clutch Leakage Check

Lube Circuit Check

Speed Sensor Test

ISO Particle Count