Bench Test Procedure for a D5M, D5N, D6M, D6N Track-Type Tractor, and 561N Pipelayer Transmission{3030, 3073, 3139} Caterpillar

Pipelayer:

561N (S/N: TAD1-UP; CPH1-UP)

Track-Type Tractor:

D5M (S/N: 6GN1-UP; 3CR1-UP; 7LR1-UP; 4JS1-UP; 5ES1-UP; 6AS1-UP)

D5N (S/N: AKD1-UP; AGG1-UP; CFH1-UP; CKT1-UP)

D6M (S/N: 3WN1-UP; 4JN1-UP; 5NR1-UP; 6LR1-UP; 4HS1-UP)

D6N (S/N: CBF1-UP; CCG1-UP; ALH1-UP; CBJ1-UP; ALR1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS1326
05	Standardized
04	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 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

Table 2

Machine Model	Transmission Arrangement
D5M	107-7300, 175-1169
D5N	200-8643
D6M	180-4716
D6N	175-1171

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, it is important 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.

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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

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9584	Rail As	1
	1U-9586	Swivel Head Support Gp	1
	9U-9768	Plate	1
	9S-1366	Bolt (1/2-13 X 2.50 inch)	3
	5P-8245	Hard Washer	3
B	108-4561 (1)	Yoke As	1
	108-8296 (2)	Yoke As	1
C	4C-4687	Drive Adapter	1
	8T-2223	Bolt (M10 X1.5 X 45 mm)	4
	6V-5839	Washer	4
D	136-3647	Drive Adapter As	1
	0S-1594	Bolt (3/8-16 X 1 inch)	4
	5M-2894	Hard Washer	4
E	1U-9131	Drive Adapter (Key)	1
	0L-1351	Bolt (3/8-16 X .875 inch)	4
	5M-2894	Hard Washer	4
F	1U-9769	Adapter	1
	8C-9024	Fitting As (Plain)	2
	4J-0519	O-Ring Seal	2
	7X-0326	Bolt (1/2-13 X 3.00 inch)	1
	7X-0328	Bolt (1/2-13 X 3.50 inch)	1
	8T-4223	Hard Washer	4
	6V-8188	Nut	2
G	439-3940	Link Bracket As	4
	8T-8917	Bolt (1/2-13 X 1.25 inch)	2
	5P-2424	Bolt (1/2-13 X 2.25 inch)	2
	8T-4223	Hard Washer	6
	6V-8188	Nut	3
	1U-9722	Load Binder As (Ratchet Type)	4
H	1U-9767	Adapter	1
	4J-0519	O-Ring Seal	1
	8C-9024	Fitting As (Plain)	1
	7X-0341	Bolt (1/2-13 X 7 inch)	2
	8T-4223	Hard Washer	4
	6V-8188	Nut	2
P	221-9136	Bypass Adapter	1
	8C-9024	Fitting As (Plain)	1
J	6V-3965	Fitting As (Quick Disconnect)	2
	3J-1907	O-Ring Seal	2
K	9U-7500	Transmission Analyzer Tool Gp	1
	OR
	277-2362	Transmission Analyzer III Gp	1
	306-0397	Extension Cable (Transmission Analyzer)	1
	256-7623	Adapter Cable As (Test)	1
L	146-4080	Digital Multimeter	1
M	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	1
	6V-4144	Coupler	1
N	8T-0853	Pressure Gauge (0 to 400 kPa (0 to 58 psi))	1
	6V-4144	Coupler	1

( 1 )	This tool is required for the D5M transmission.
( 2 )	This tool is required for the D6M transmission.

Installation Procedure

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Illustration 3	g00891011

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

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Illustration 4	g03858471

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

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Illustration 5	g00891013

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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Illustration 6	g00891014

4. Install Tooling (B) on the input shaft.

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Illustration 7	g00891015

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

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Illustration 8	g00891016

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

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Illustration 9	g00891018

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

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Illustration 10	g00891019

8. Align the transmission to the input drive shaft.

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

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Illustration 11	g00891020

10. Close and latch the drive shaft guard.

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Illustration 12	g03802221

11. Tighten all four castle nuts and jack bolts.

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Illustration 13	g00891021

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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Illustration 14	g00891022

13. Install Tooling (G) to the rear of the transmission to prevent movement during testing.

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Illustration 15	g00891024

14. Install Tooling (G) to the input end of the transmission to prevent movement during testing.

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Illustration 16	g00891025

15. Install Tooling (H) on the transmission case.

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Illustration 17	g00891027

16. Remove plug (1) .

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Illustration 18	g03858463

17. Install Tooling (P) .

18. Remove two plugs (2) .

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Illustration 19	g00891029

19. Install Tooling (J) .

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Illustration 20	g00891031

20. Connect hose assembly (3) from pressurized flow meter to Tooling (F) .

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

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Illustration 21	g00891032

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

24. Connect pressure gauge (7) to Tooling (J) .

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Illustration 24	g00891037

25. Connect Tooling (K) to the transmission.

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Illustration 25	g00891038
Ground Clamp

26. Connect Tooling (K) 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 (K)

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Illustration 28	g01457869
Tooling (K)

28. Connect Tooling (K) to a power source. Refer to Tool Operating Manual, NEHS0644 orTool 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 "D5M-24V", "D6M-24V", or "D6N-24V".

Harness Test (TA3 only)

1. Make sure that the harness is properly connected.

2. Use Tooling (K) 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 (K) 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 Testing and Adjusting, SENR8486, "D5M Track-Type Tractor Power Train", Systems Operation, Testing and Adjusting, RENR5285, "D5N Track-Type Tractor Power Train", Testing and Adjusting, SENR8386, "D6M Track-Type Tractor Power Train", orSystems Operation, Testing and Adjusting, RENR5265, "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. If you are testing a D5M, or D5N transmission then adjust the input rotation to 850 ± 30 rpm. If you are testing a D6M, or D6N transmission then adjust the input rotation to 800 ± 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. The lubrication pressure must be between 47 kPa (7 psi) and 63 kPa (9 psi).

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

8. Record the value in Table 7.

Clutch Leakage Check

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

2. If you are testing a D5M, or D5N transmission then adjust the input rotation to 2100 ± 30 rpm in the NEUTRAL position. If you are testing a D6M, or D6N transmission then adjust the input rotation to 2200 ± 30 rpm in the NEUTRAL position.

3. The lubrication pressure must be between 200 kPa (29 psi) and 230 kPa (33.4 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 800 ± 30 rpm.

6. Shift the transmission to FORWARD 1.

7. Adjust the input rotation to 2100 ± 30 rpm if you are testing a D5M, or D5N transmission. Adjust the input rotation to 2200 ± 30 rpm if you are testing a D6M, or D6N transmission.

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 800 ± 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 800 ± 30 rpm.

3. Shift the transmission to FORWARD 2.

4. Adjust the input rotation to 2100 ± 30 rpm if you are testing a D5M, or D5N transmission. Adjust the input rotation to 2200 ± 30 rpm if you are testing a D6M, or D6N transmission.

5. The lubrication pressure must be between 9 kPa (2 psi) of the average for this transmission arrangement. Reference is 150 - 168 kPa (22 - 24 psi).

6. Record the value in Table 9.

Speed Sensor Test

Note: Not all transmission arrangements will have intermediate speed sensors.

1. Adjust the input flow to 37 ± 4 L/min (10 ± 1 US gpm).

2. Adjust the input rotation to 800 ± 5 rpm.

3. Shift the transmission to FORWARD 1.

4. Adjust the input rotation to 850 ± 5 rpm if you are testing a D5M, or D5N transmission. Adjust the input rotation to 800 ± 5 rpm if you are testing a D6M, or D6N transmission.

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Illustration 30	g00891039

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

6. Record the values in Table 10.

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

8. Adjust the input rotation to 800 ± 5 rpm.

9. Shift the transmission to FORWARD 2.

10. Use Tooling (L) 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 10.

Transmission Bench Test Data Sheet

Table 5

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

Solenoid Test

Table 6

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

Start Checks

Table 7

Lubrication Pressure

Input Speed "D5M" or "D5N" (850 ± 30 rpm) Input Speed "D6M" or "D6N" (800 ± 30 rpm) Input Flow 38 ± 4 L/min (10 ± 1 US gpm) Supply Pressure 3000 ± 70 kPa (435 ± 10 psi)

_______kPa _______(psi)

Clutch Leakage Check

Table 8

Clutch Leakage Check		Input Speed "D5M" or "D5N" (2100 ± 30 rpm) Input Speed "D6M" or "D6N" (2200 ± 30 rpm) Input Flow 75 ± 4 L/min (20 ± 1 US gpm) Supply Pressure 3100 ± 205 kPa (450 ± 30 psi) Lubrication pressure MUST BE between 200 kPa (29 psi) and 230 kPa (33 psi) to continue.
Gear Range	1F	2F	3F	1R	2R	3R	N
Input Flow	______	______	______	______	______	______	______
Output Flow	______	______	______	______	______	______	______
Leakage	______	______	______	______	______	______	______
Average of Arrangement	______	______	______	______	______	______	______

Lube Circuit Check

Table 9

Lube Circuit Check		Gear Range FORWARD 2 Input Speed "D5M" or "D5N" (2100 ± 30 rpm) Input Speed "D6M" or "D6N" (2200 ± 30 rpm) Lube Flow 76 ± 1 L/min (20 ± 1 US gpm)
Average Lubrication Pressure Of Arrangement	_______kPa _______(psi)	Lubrication Pressure	_______kPa _______(psi)

Speed Sensor Test

Table 10

Sensor	Minimum Voltage
	D5M D5N	D6M D6N
Intermediate Speed Sensor 1	3.4 Vrms
Intermediate Speed Sensor 2	3.4 Vrms
Output Speed Sensor 1	1.1 Vrms	1.6 Vrms
Output Speed Sensor 2	1.1 Vrms	1.6 Vrms

Table 11

Speed Sensor Test	Input Speed "D5M" or "D5N" (850 ± 5 rpm) Input Speed "D6M" or "D6N" (800 ± 5 rpm) Input Flow 38 ± 4 L/min (10 ± 1 US gpm) Supply Pressure 3000 ± 70 kPa (435 ± 10 psi)
Sensor	Gear Range
	FORWARD 1	FORWARD 2
Intermediate Speed Sensor 1	_____________ Vrms	_____________Vrms
Intermediate Speed Sensor 2	______________Vrms	_____________Vrms
Output Speed Sensor 1	_____________Vrms	______________Vrms
Output Speed Sensor 2	______________Vrms	______________Vrms

ISO Particle Count

Table 12

ISO Particle Count

Sample the test bench oil supply.

________/________Particle Count

Table 13

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______________________________________ Supervisor