Bench Test Procedure For A D10T Track-Type Tractor Transmission{3030, 3073} Caterpillar

Track-Type Tractor:

D10T (S/N: RJG1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS3183
06	Standardized.
05	Updated Table 12.
04	Updated Introduction and Tables 12 and 13.
03	Updated Introduction and Tables 12 and 13.
02	Added new introduction and Canceled Part Numbers section.

© 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 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 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 issue, use the following resources in order 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
D10T	213-5171

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 in order 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, to 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 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.

Show/hide table

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.

Show/hide table

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Show/hide table

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 Table3 were used to develop this test procedure.

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9584	Rail As	1
	FT-2979	Support Assembly (1)	1
	4C-4768	Support	1
B	110-9311	Yoke As	1
C	4C-4627	Adapter	1
	0S-1613	Bolt (1/2-20X1.5 inch)	4
	5P-8245	Hard Washer	4
D	136-3647	Drive Adapter Assembly	1
	0S-1594	Bolt (3/8-16X1 inch)	4
	5M-2894	Hard Washer	4
E	1U-9131	Drive Adapter (Key)	1
	0L-1351	Bolt (3/8-16X7/8 inch)	4
F	439-3939	Link Bracket As	2
	1A-0458	Bolt (3/4-10X1.75 inch)	2
	4B-5273	Washer	2
	1U-9722	Ratcheting Turnbuckle	3
G	1U-9885	Adapter (Plate)	1
	9M-9647	O-Ring Seal	3
	8C-9024	Nipple Assembly (Plain)	3
	2A-1531	Bolt (1/2-13X6.5 inch)	2
	5P-8245	Hard Washer	4
	1F-7958	Full Nut	2
H	9U-7500	Transmission Analyzer Tool Gp	1
	OR
	277-2362	Transmission Analyzer III Gp	1
	306-0397	Extension Cable	1
	256-7623	Adapter Cable Assembly (Test) (2)	1
	300-4993	Adapter Cable Assembly (Test) (3)	1
M	146-4080	Digital Multimeter	1
J	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	1
	6V-4144	Coupler	1
K	8T-0853	Pressure Gauge (0 to 400 kPa (0 to 58 psi))	1
	6V-4144	Coupler	1
L	6V-3965	Nipple (Quick Disconnect)	5

( 1 )	Refer to Illustration 3 for further information.
( 2 )	Use this cable for 17 pin connectors.
( 3 )	Use this cable for 14 pin connectors.

Illustration 3	g01256261

Installation Procedure

Show/hide table



Illustration 4	g03886945

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

Show/hide table



Illustration 5	g01256263

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

3. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1504 kg (3315 lb).

Show/hide table



Illustration 6	g01256264

4. Install Tooling (C) on Tooling (B) .

Show/hide table



Illustration 7	g01256265

5. Install Tooling (D) on Tooling (C) .

Show/hide table



Illustration 8	g01256267

6. Install Tooling (E) on Tooling (D) .

Show/hide table



Illustration 9	g01256268

7. Install the tooling setup on the input drive shaft.

Show/hide table



Illustration 10	g01256273

8. Align the transmission to the input drive shaft.

9. Connect the input drive shaft to Tooling (E) .

Show/hide table



Illustration 11	g01256274
Typical Example

10. Install the drive shaft guard.

Show/hide table



Illustration 12	g03802221

11. Tighten all four castle nuts and jack bolts.

Show/hide table



Illustration 13	g01256275

12. Install Tooling (F) to the transmission to prevent movement during testing.

Show/hide table



Illustration 14	g01256277

13. Install Tooling (G) in the transmission case.

Show/hide table



Illustration 15	g01256278

14. Connect hose assembly (1) from the pressurized flow meter to Tooling (G) .

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

15. Connect hose assembly (2) from Tooling (G) to the No. 2 flow meter inlet.

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

16. Connect hose assembly (3) from the No. 2 flow meter outlet to Tooling (G) .

Show/hide table



Illustration 16	g01256279
Transmission Lubrication Pressure

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

17. Connect a pressure gauge to pressure tap (4) .

Show/hide table



Illustration 17	g01256280
Main Supply Pressure

18. Connect a pressure gauge to pressure tap (5) .

Show/hide table



Illustration 18	g01256283

19. Remove cover plate (6) .

Show/hide table



Illustration 19	g01256547
(7) No. 1 clutch (8) No. 2 clutch (9) No. 4 clutch (10) No. 3 clutch (11) No. 5 clutch

20. Install Tooling (L) to locations (7), (8), (9), (10), and (11) on the transmission control group.

21. Install pressure gauges to Tooling (L) .

Show/hide table



Illustration 20	g01256289

22. Connect Tooling (H) to the transmission.

Show/hide table



Illustration 21	g01256286

23. Connect Tooling (H) to a suitable location.

Show/hide table



Illustration 22	g01256287

24. Cover the transmission. Use a suitable clean cover.

Show/hide table



Illustration 23	g01256288
Tooling (H)

Show/hide table



Illustration 24	g01457869
Tooling (H)

25. Connect Tooling (H) 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 "D10T-24V".

Harness Test (TA3 only)

1. Make sure that the harness is properly connected.

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

3. Record the values in Table 7.

   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 (H) to perform the solenoid test.

3. Record the values in Table 7.

   Note: Do not continue testing until Solenoid Test passes.

Start Checks

Note: Refer to Testing and Adjusting, RENR7547, "D10T Track-Type Tractor Power Train".

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 64 ± 4 L/min (17 ± 1 US gpm).

3. Check the supply pressure. The correct supply pressure is 2790 ± 70 kPa (405 ± 10 psi).

Show/hide table



Illustration 25	g02720621

4. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 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. The lubrication pressure must be between 21 kPa (3 psi) and 35 kPa (5 psi) to continue.

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

6. Record the value in Table 8.

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

8. Confirm the correct clutch engagement with Table 4.
   Show/hide table

   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

Clutch Leakage Check

1. Adjust the input flow to 189 ± 4 L/min (50 ± 1 US gpm).

2. Adjust the input rotation to 2130 ± 30 rpm in the NEUTRAL position.

3. The lubrication pressure must be between 220 kPa (32 psi) and 245 kPa (35 psi) to continue.

4. Record the value in Table 9.

5. Check the supply pressure. The correct supply pressure is 3150 ± 138 kPa (457 ± 20 psi).

6. Adjust the input rotation to 700 ± 30 rpm.

7. Shift the transmission to FORWARD 1.

8. Adjust the input rotation to 2130 ± 30 rpm.

9. Record the input flow in Table 9.

10. Record the output flow in Table 9.

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

12. Record the calculation in Table 9.

13. Adjust the input rotation to 700 ± 30 rpm.

14. Shift the transmission through positions FORWARD 2, FORWARD 3, REVERSE 1, REVERSE 2, REVERSE 3, and NEUTRAL. Repeat Steps 8 through 12 for each gear range.

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

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

16. The difference in leakage between FIRST gear and all other gears must not exceed 3.0 ± 0.8 L/min (0.8 ± 0.2 US gpm) of the average for this arrangement. Reference for the maximum allowable leakage is 6.1 ± 3.0 L/min (1.6 ± 0.8 US gpm).

    Note: Refer to ""Collecting the Test Data" " for further information.

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 700 ± 30 rpm.

3. Shift the transmission to FORWARD 2.

4. Adjust the input rotation to 2130 ± 30 rpm.

5. The lubrication pressure must be within 7 kPa (1 psi) of the average for this transmission arrangement. Reference is 76 ± 7 kPa (11 ± 1 psi).

   Note: Refer to ""Collecting the Test Data" " for further information.

6. Record the value in Table 10.

Speed Sensor Test

Note: This transmission arrangement has two speed sensors that must be tested.

1. Adjust the input flow to 53 ± 4 L/min (14 ± 1 US gpm).

2. Adjust the input rotation to 700 ± 5 rpm.

3. Shift the transmission to FORWARD 1.

Show/hide table



Illustration 26	g03372856

4. Connect Tooling (M) to Tooling (H) .

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

6. Record the values in Table 11.

7. The minimum voltage should be 2.1 V for each speed sensor.

High Idle Pressure Check

1. Adjust the input flow to 189 ± 4 L/min (50 ± 1 US gpm).

2. Adjust the input rotation to 700 ± 30 rpm.

3. Shift the transmission into FORWARD 1.

4. Adjust the input rotation to 2130 ± 30 rpm.

5. Record the pressure values in Table 13.

6. Repeat Steps 1 through 5 for all gear ranges.

Transmission Bench Test Data Sheet

Table 5

CATERPILLAR	Transmission Bench Test Data Sheet	Test Date:_______
		Model:_______
Work Order:_______		Serial No.:_______

Specifications

Table 6

Specifications
Description	High Idle	Low Idle
Input Speed	2130 ± 30 rpm	700 ± 30 rpm
Pressures
Supply Pressure	3150 ± 138 kPa (457 ± 20 psi)	2790 ± 70 kPa (405 ± 10 psi)
Lubrication Pressure	221 kPa (32 psi)	28 kPa (4 psi)

Solenoid Test

Table 7

Solenoid Test	Solenoid 1	Solenoid 2	Solenoid 3	Solenoid 4	Solenoid 5
	________ ohms	________ ohms	________ ohms	________ ohms	________ ohms

Start Checks

Table 8

Lubrication Pressure

Input Speed (700 ± 30 rpm) Input Flow 64 ± 4 L/min (17 ± 1 US gpm) Supply Pressure 2790 ± 70 kPa (405 ± 10 psi)

_______kPa _______(psi)

Clutch Leakage Check

Table 9

Clutch Leakage Check		Input Speed (2130 ± 30 rpm) Input Flow 189 ± 4 L/min (50 ± 1 US gpm) Supply Pressure 3150 ± 138 kPa (457 ± 20 psi)
Gear Range	1F	2F	3F	1R	2R	3R	N
Input Flow	______	______	______	______	______	______	______
Output Flow	______	______	______	______	______	______	______
Leakage	______	______	______	______	______	______	______
Average of Arrangement	______	______	______	______	______	______	______

Lube Circuit Check

Table 10

Lube Circuit Check		Gear Range FORWARD 2 Input Speed (2130 ± 30 rpm) Lube Flow 76 ± 4 L/min (20 ± 1 US gpm)
Average Lubrication Pressure Of Arrangement	_______kPa _______(psi)	Lubrication Pressure	_______kPa _______(psi)

Speed Sensor Test

Table 11

Speed Sensor Test	Input Speed (700 ± 5 rpm) Input Flow 53 ± 4 L/min (14 ± 1 US gpm) Gear Range FORWARD 1
Output Speed Sensor 1	__________________ volts
Output Speed Sensor 2	__________________ volts

High Idle Pressure Check

Table 12

Final Pressure Checks (High Idle)		Input speed ( 2130 ± 30 rpm) Input flow 189 ± 4 L/min (50 ± 1 US gpm)
Clutch		No. 1	No. 2	No. 3	No. 4	No. 5
Speed Position	Engaged Clutches	Pressure (1)	Pressure (1)	Pressure (1)	Pressure (1)	Pressure (2)
NEUTRAL	3			2790 kPa (405 psi)
FORWARD 1	2 and 5		2790 kPa (405 psi)			2790 kPa (405 psi)
FORWARD 2	2 and 4		2790 kPa (405 psi)		2790 kPa (405 psi)
FORWARD 3	2 and 3		2790 kPa (405 psi)	2790 kPa (405 psi)
REVERSE 1	1 and 5	2790 kPa (405 psi)				790 2205 kPa (405 psi)
REVERSE 2	1 and 4	2790 kPa (405 psi)			2790 kPa (405 psi)
REVERSE 3	1 and 3	2790 kPa (405 psi)		2790 kPa (405 psi)

( 1 )	The Tolerance is ± 100 kPa ( ± 14 psi).
( 2 )	The Tolerance is ± 200 kPa ( ± 29 psi).

Table 13

Final Pressure Checks (High Idle)		Input speed ( 2130 ± 30 rpm) Input flow 189 ± 4 L/min (50 ± 1 US gpm)
Clutch		No. 1	No. 2	No. 3	No. 4	No. 5
Speed Position	Engaged Clutches	Pressure	Pressure	Pressure	Pressure	Pressure
NEUTRAL	3
FORWARD 1	2 and 5
FORWARD 2	2 and 4
FORWARD 3	2 and 3
REVERSE 1	1 and 5
REVERSE 2	1 and 4
REVERSE 3	1 and 3

ISO Particle Count

Table 14

ISO Particle Count

Sample the test bench oil supply.

________/________Particle Count

Table 15

______________________________________ Technician

______________________________________ Supervisor