Bench Test Procedure for a D6H Track-Type Tractor Transmission {3030, 3073} Caterpillar

Track-Type Tractor

D6H (S/N: 4RC1-UP; 6FC1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS2285
02	Standardized.
01	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-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. This 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 need, 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

Table 2

Machine Model	Transmission Arrangement
D6H	7G-4636

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 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 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. For additional information about tooling, consult Dealer Service Tools Division.

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9584	Rail As	2
	1U-9586	Swivel Head Support Gp	1
B(1)	3T-8305	Yoke As	1
	9G-1930	Yoke As	1
C	4C-4687	Drive Adapter	1
	0L-0478	Bolt (3/8-24X1.75 inch)	4
	3B-4506	Lockwasher	4
	4C-4627	Adapter	1
	0S-1629	Bolt (1/2-20X1 inch)	4
	3B-4509	Lockwasher	4
D	136-3647	Drive Adapter As	1
	0S-1594	Bolt (3/8-16X1 inch)	4
	3B-4506	Lockwasher	4
E	1U-9131	Drive Adapter (Key)	1
F	439-3940	Link Bracket As	2
	0L-1329	Bolt (1/2-13X3 inch)	2
	4B-5273	Washer	2
	1D-4719	Full Nut	2
	1U-9722	Ratcheting Turnbuckle	2
G	1U-7044	Lube Adapter	1
	4J-0520	O-Ring Seal	3
	8C-9024	Nipple Assembly (Plain)	3
	6V-3966	Nipple Assembly (Valve)	3
	7X-0341	Bolt (1/2-13X7 inch)	2
	8T-4223	Hard Washer	4
	6V-8188	Nut	2
H	8C-9024	Fitting As (Plain)	1
	8C-9025	Quick Coupler	1
	3B-7749	Fitting	1
	120-6843	Ball Valve	1
J	175-2599	Plug (Expandable)	1
K	6V-3965	Nipple Assembly (Valve)	1
	3J-1907	O-Ring	1
L	2M-2829	Control Lever	1
	0L-1170	Handle	1
	9H-6673	Pin	1
	6S-6646	Lock Pin	1
M	4M-7307	Control Lever	1
	0L-1170	Handle	1
	9H-6673	Pin	1
	6S-6646	Lock Pin	1
N	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	1
	6V-4144	Coupler	1
P	8T-0853	Pressure Gauge (0 to 400 kPa (0 to 58 psi))	1
	6V-4144	Coupler	1

(1)	The yoke assemblies are interchangeable. The yoke may be removed from the main drive shaft to be used during the test.

Installation Procedure

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Illustration 3	g00877490

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

   Note: Use the existing transmission bolts.

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   Illustration 4	g00877491

2. Use a hoist to install the transmission on the test bench. The weight of the transmission is 838 kg (1850 lb).
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   Illustration 5	g00877492

3. Install Tooling (B) on the input shaft.
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   Illustration 6	g00877493

4. Install Tooling (C) on Tooling (B).
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   Illustration 7	g00877494

5. Install Tooling (D) on Tooling (C).
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   Illustration 8	g00877513

6. Install Tooling (E) on Tooling (D).
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   Illustration 9	g00877495

7. Align the transmission to the input drive shaft.

8. Connect the input drive shaft to Tooling (E).
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   Illustration 10	g00877496

9. Install the drive shaft guard.
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   Illustration 11	g03802221

10. Tighten all four castle nuts and jack bolts.
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    Illustration 12	g00877497

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    Illustration 13	g00877498

11. Install Tooling (F) to the transmission to prevent movement during testing.
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    Illustration 14	g00877499

12. Install Tooling (G) in the transmission case.
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    Illustration 15	g02174715

13. Install tooling (H) onto Tooling (G).
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    Illustration 16	g00877500

14. Remove plug (1).
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    Illustration 17	g02174721

15. Install Tooling (J).
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    Illustration 18	g02174734
    (2) Main Relief Valve (Main Supply Pressure)

16. Connect hose assembly (2) from the pressurized flow meter to Tooling (G).

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

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    Illustration 19	g02174735
    (3) Oil to No. 2 Flow Meter Inlet

17. Connect hose assembly (3) from Tooling (H) 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.

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    Illustration 20	g02174736
    (4) Lube Oil From No. 2 Flow Meter

18. Connect hose assembly (4) from the No. 2 flow meter outlet to Tooling (G).
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    Illustration 21	g02174750
    (5) Transmission Main Relief Valve (Main Supply Pressure) (6) Transmission Converter Inlet Oil Pressure "P3" (7) Transmission Lube Pressure

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

19. Connect pressure gauges to pressure taps (5), (6), and (7).
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    Illustration 22	g02174752

20. Remove cover plate (8).
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    Illustration 23	g02175006

21. Install Tooling (K).
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    Illustration 24	g02175014

22. Remove cover (9).
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    Illustration 25	g02175017
    Direction Selector

23. Install Tooling (L).
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    Illustration 26	g02175020
    Speed Selector

24. Install Tooling (M).

25. Install cover (9).
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    Illustration 27	g02175023
    (10) "P2" Speed Clutch Pressure (11) "P1" Direction Clutch Pressure

26. Connect pressure gauge (10) to Tooling (K).

27. Connect pressure gauge (11) to Tooling (K).
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    Illustration 28	g00877509

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

Test Procedure

Start Checks

Note: Refer to Testing and Adjusting, SENR3241, "D6H & D6H Series II Tractors Power Shift Transmission" 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 48 ± 4 L/min (12 ± 1 US gpm).
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   Illustration 29	g02720621

3. 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.

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   Illustration 30	g01091561

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

5. Confirm 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

6. Stop the input shaft.

Initial Pressure Check

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Illustration 31	g00995162
Top View

1. Remove the load piston plug from the top of the transmission control valve.

2. Adjust the input flow to 48 ± 4 L/min (12 ± 1 US gpm).

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 30 rpm.

4. The "P1" pressure must be 531 ± 34 kPa (77 ± 5 psi).

5. Record the value in Table 7.

6. The pressure for the priority valve must be 2896 ± 134 kPa (420 ± 20 psi). This pressure is measured at pressure tap (5).

7. Record the value in Table 7.

8. Stop the input rotation.

9. Stop the input flow.

10. Install the load piston plug.

Torque Converter Inlet Ratio Valve Check

1. Adjust the input flow to 48 ± 4 L/min (12 ± 1 US gpm). Maintain this flow during this check.

2. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 30 rpm.

3. Shift the transmission to FORWARD 1.

4. Use Tooling (H) to momentarily block the supply for the torque converter.

5. The "P3" pressure must be 951 ± 55 kPa (138 ± 8 psi). This pressure is measured at pressure tap (6).

6. Open Tooling (H).

7. Record the value in Table 8.

Valve Check (Pressure Differential)

1. Shift the transmission to the FORWARD 3.

2. Adjust the input flow to 48 ± 4 L/min (12 ± 1 US gpm).

3. Adjust the input rotation to 700 ± 30 rpm. The "P2" pressure must be 0 kPa (0 psi).

4. Shift the transmission into the NEUTRAL position.

5. Shift the transmission into any gear range.

6. "P1" pressure must be a minimum of 2206 kPa (320 psi).

7. The "P2" pressure must rise to normal pressure.

8. Record the value in Table 9.

9. Shift the transmission to NEUTRAL.

Lube Circuit Check

1. Adjust the input flow until the lube flow is 64 ± 4 L/min (16 ± 1 US gpm).

2. Shift the transmission to FORWARD 2.

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

4. Adjust the input rotation to 1800 ± 30 rpm.

5. The lube pressure must be within ± 14 kPa (± 2 psi) of the average for this transmission arrangement. Reference is 162 ± 14 kPa (24 ± 2 psi).

6. Record the value in Table 10.

Clutch Leakage Check

1. Adjust the input flow to 114 ± 1 L/min (30 ± 1 US gpm). Maintain this flow during this check.

2. Adjust the input rotation to 700 ± 30 rpm in the NEUTRAL position.

3. Shift the transmission to FORWARD 1.

4. Adjust the input rotation to 1800 ± 30 rpm in the FORWARD 1 position.

5. Record the input flow in Table 11.

6. Record the output flow in Table 11.

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

8. Record the calculation in Table 11.

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

10. Shift the transmission through positions FORWARD 2, FORWARD 3, REVERSE 1, REVERSE 2, REVERSE 3, and NEUTRAL. Repeat Steps 4 through 9 for each gear range.

    Note: Always return to NEUTRAL when shifting between FORWARD and REVERSE.

11. 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).

12. The difference in leakage between FIRST gear and all other gears must not exceed 3 L/min (0.8 US gpm) of the average for this arrangement. Reference is 5.3 ± 3 L/min (1.4 ± 0.8 US gpm).

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

Table 5

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

Specifications

Table 6

General Specifications
Description	High Idle	Low Idle
Input Speed	1800 ± 30 rpm	700 ± 30 rpm
Input Flow	114 ± 4 L/min (30 ± 1 US gpm)	48 ± 4 L/min (12 ± 1 US gpm)
Minimum Lube Flow	102 L/min (27 US gpm)	27 L/min (7 US gpm)
Pressures
"P1" Initial(1)		531 ± 34 kPa (77 ± 5 psi)
Priority Valve(1)		2896 ± 134 kPa (420 ± 20 psi)
P1	2620 ± 140 kPa (380 ± 20 psi)	2206 kPa (320 psi) min
P2	P1 − 379 ± 55 kPa (P1 − 55 ± 8 psi)	P1 − 379 ± 55 kPa (P1 − 55 ± 8 psi)
P3(2)		951 ± 55 kPa (138 ± 8 psi)
Lube	303 ± 41 kPa (44 ± 6 psi)	28 kPa (4 psi) Minimum

(1)	The load piston plug is removed and the transmission is in the NEUTRAL position.
(2)	The flow for the torque converter outlet is restricted.

Initial Pressure Check

Table 7

Initial Pressure

Input Speed (700 ± 30 rpm) Input Flow 48 ± 4 L/min (12 ± 1 US gpm)

______kPa ______(psi)

Torque Converter Inlet Ratio Valve Check

Table 8

Torque Converter Inlet Ratio Valve Pressure

Input Speed (700 ± 30 rpm) Input Flow 48 ± 4 L/min (12 ± 1 US gpm)

______kPa ______(psi)

Valve Check (Pressure Differential)

Table 9

Valve Check (Pressure Differential)
Input Flow	Input Speed	Gear Range	"P2" Pressure
48 ± 4 L/min (12 ± 1 US gpm)	700 ± 30 rpm	F3	______kPa ______(psi)
114 ± 4 L/min (30 ± 1 US gpm)	1800 ± 30 rpm	F3	______kPa ______(psi)
		N then shift to any gear range.	______kPa ______(psi)

Lube Circuit Check

Table 10

Lube Circuit Check		Gear Range FORWARD 2 Input Speed (1800 ± 30 rpm) Lube Flow 76 ± 4 L/min (20 ± 1 US gpm)
Average Lube Pressure Of Arrangement	______kPa ______(psi)	Lube Pressure	______kPa ______(psi)

Clutch Leakage Check

Table 11

Clutch Leakage Check			Input Speed (1800 ± 30 rpm) Input Flow 114 ± 4 L/min (30 ± 1 US gpm)
Gear Range	N	F1	F2	F3	R1	R2	R3
Input Flow	______	______	______	______	______	______	______
Output Flow	______	______	______	______	______	______	______
Leakage	______	______	______	______	______	______	______
Average of Arrangement	______	______	______	______	______	______	______

Contamination Control

Table 12

ISO Particle Count

Sample the test bench oil supply.

________/________Particle Count

Table 13

______________________________________ Technician

______________________________________ Supervisor