Bench Test Procedure for a D4E Track-Type Tractor Transmission{3030, 3073} Caterpillar

Track-Type Tractor:

D4E (S/N: 28X1-UP)

Introduction

This special instruction contains the necessary information that is required to bench test specific transmission arrangements. Refer to Table 1 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 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, please 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 1

Machine Model	Transmission Arrangement
D4E	8P-4917
D4E	8P-4919

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.

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.

Required Tools

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 2 were used in order to develop this test procedure.

Table 2

Required Tools
Tooling	Tool Number	Part Description	Qty
A	FT-0668	Spacer	1
	FT-0669	Drive Adapter	1
	5M-7342	Yoke As	1
	0T-0924	Bolt (3/8-24x1.5 inch)	4
	FT-0715	Compression Plate	1
	6B-7021	O-Ring Seal	1
	0S-1616	Bolt (1/4-20x1 inch)	1
B	8C-9024	Nipple (Quick Disconnect)	1
	5P-0492	Adapter	1
	7M-8485	O-Ring Seal	1
C	9U-7444	Adapter (Flange)	1
	1P-4577	Split Flange	2
	3B-7749	Nipple (Pipe)	1
	7X-7646	Nipple (Quick Disconnect)	1
D	7X-7646	Nipple (Quick Disconnect)	1
	3B-7749	Nipple (Pipe)	1
	1U-8303	Fitting	1
	1P-4577	Split Flange	2
E	8C-9024	Nipple (Quick Disconnect)	1
	1U-8303	Fitting	1
	8C-9025	Coupler (Quick Disconnect)	1
	7X-7646	Nipple (Quick Disconnect)	1
	6B-9081	Bushing	2
	7F-6654	Nipple (Pipe)	2
	120-6843	Ball Valve	1
F	7S-8887	Nipple (Quick Disconnect)	1
	5P-3501	Adapter	1
	3J-1907	O-Ring Seal	1
G	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
H	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
J	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
K	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
L	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
M	8S-4628	Test Cover	1
N	5S-4492	Shipping Cover	1
P	6K-8298	Flange Assembly	1
	3J-5390	Plug ((3/8 inch NPT))	1

Installation Procedure

Show/hide table



Illustration 1	g01299024
Typical example

1. Use the hoist to install the transmission on the test bench. The weight of the transmission is 526.16 kg (1160 lb).

2. Secure the transmission to the test bench.

   Note: In some cases, a steering clutch pump is attached to the front of the transmission. Remove the pump from the transmission prior to testing. Cover the opening with a small plate in order to confine oil spray.

Show/hide table



Illustration 2	g01299038

3. Install Tooling (A) onto the input shaft of the transmission.

Show/hide table



Illustration 3	g01299070
Typical example

4. Align the transmission to the input drive shaft.

5. Connect the input drive shaft to Tooling (A) .

Show/hide table



Illustration 4	g01299073
Typical example

6. Install the drive shaft guard.

7. Secure the transmission to the test bench in order to prevent movement during testing.

Show/hide table



Illustration 5	g01299081

8. Install Tooling (B) .

Show/hide table



Illustration 6	g01299093

9. Connect hose (1) from Tooling (B) to the inlet of the "Number 1" flow meter on the test bench.

Show/hide table



Illustration 7	g01299168

10. Install Tooling (C) .

Show/hide table



Illustration 8	g01299173

11. Connect hose (2) from the outlet of the "Number 1" flow meter on the test bench to Tooling (C) .

Show/hide table



Illustration 9	g01299280

12. Install Tooling (D) .

Show/hide table



Illustration 10	g01299288

13. Connect hose (3) from Tooling (D) to the inlet of the "Number 2" flow meter on the test bench.

Show/hide table



Illustration 11	g01299421

14. Install Tooling (E) .

Show/hide table



Illustration 12	g01299430

15. Connect hose (4) from the outlet of the "Number 2" flow meter on the test bench to Tooling (E) .

Show/hide table



Illustration 13	g01299486

16. Remove threaded plug (5) .

Show/hide table



Illustration 14	g01299487

17. Install Tooling (F) .

Show/hide table



Illustration 15	g01299453
Torque Converter Outlet Pressure (6)

18. Connect pressure tap (6) to Tooling (F) .

19. Remove the top cover from the transmission.

Show/hide table



Illustration 16	g01299619

20. Remove threaded plug (7) .

Show/hide table



Illustration 17	g01299516

21. Install Tooling (G) .

Show/hide table



Illustration 18	g01299514
Priority Valve Pressure (8)

22. Connect pressure tap (8) to Tooling (G) .

23. Remove the cover from the top of the transmission.

Show/hide table



Illustration 19	g01299627

24. Remove threaded plug (9), threaded plug (10), threaded plug (11), and threaded plug (12) from the top of the hydraulic controls.

Show/hide table



Illustration 20	g01301014

25. Install Tooling (H) .

Show/hide table



Illustration 21	g01301002

26. Install Tooling (J) .

Show/hide table



Illustration 22	g01300373

27. Install Tooling (K) .

Show/hide table



Illustration 23	g01299994

28. Install Tooling (L) .

Show/hide table



Illustration 24	g01299986

29. Install Tooling (M) .

Show/hide table



Illustration 25	g01299798
Lubrication Pressure (13)

30. Connect pressure tap (13) to Tooling (H) .

Show/hide table



Illustration 26	g01299797
Speed Clutch Pressure "P1" (14)

31. Connect pressure tap (14) to Tooling (J) .

Show/hide table



Illustration 27	g01299793
Directional Clutch Pressure "P2" (15)

32. Connect pressure tap (15) to Tooling (K) .

Show/hide table



Illustration 28	g01299734
Torque Converter Inlet Pressure "P3" (16)

33. Connect pressure tap (16) to Tooling (L) .

Show/hide table



Illustration 29	g01301026

34. Install Tooling (N) .

Show/hide table



Illustration 30	g01301077

35. Install Tooling (P) .

Show/hide table



Illustration 31	g01301287

36. Remove plug (17) from Tooling (P) .

37. Supply oil to the transmission, the oil lines and the transfer gear housing until oil flows out of the opening in Tooling (P) .

38. Install plug (17) .

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

Test Procedure

Preliminary Checks

Note: Refer to Testing and Adjusting, SENR7632, "D4E 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.

Show/hide table



Illustration 32	g01301309

2. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 600 ± 10 rpm.

   Note: The input shaft will be rotated in a counterclockwise direction for the duration of the test. The direction is determined as you face the drive motor of the test bench.

3. Shift the transmission through all directions and through all speed ranges in order to eliminate air from the transmission controls.

4. Check for lockup or excessive drag in all speed ranges.

5. Stop the input rotation.

Initial Pressure Check

1. Adjust the input rotation to 600 ± 10 rpm.

2. Shift the transmission into the NEUTRAL position.

3. Initial "P1" pressure must be 586.05 ± 34.47 kPa (85 ± 5 psi).

4. Record the value in Table 5.

Priority Valve Pressure Check

1. Adjust the input rotation to 600 ± 10 rpm.

2. Shift the transmission into the NEUTRAL position.

3. The pressure at the priority valve must be 1654.74 ± 68.94 kPa (240 ± 10 psi).

4. Record the value in Table 6.

Safety Valve Check

1. Adjust the input rotation to 600 ± 10 rpm.

2. Shift the transmission into any gear range except NEUTRAL.

3. Shift the transmission into the NEUTRAL position.

4. Shift the transmission back into the selected gear range.

5. "P2" pressure must remain at 0.00 ± 0.00 kPa (0 ± 0 psi) until the transmission is shifted from the selected gear range into NEUTRAL then back into gear.

6. "P1" pressure must be a minimum of 1896.05 kPa (275 psi) after the transmission has been shifted from the selected gear range into NEUTRAL then back into gear.

7. "P2" pressure must equal "P1" minus 344.74 ± 55.15 kPa (50 ± 8 psi) pressure after the transmission has been shifted from the selected gear range into NEUTRAL then back into gear.

8. Record the values in Table 7.

Torque Converter Ratio Valve Check

1. Adjust the input rotation to 600 ± 10 rpm.

2. Shift the transmission into any gear range except NEUTRAL.

3. Adjust Tooling (E) in order to temporarily block lubrication flow to the torque converter.

4. "P3" pressure must be 706.71 ± 51.71 kPa (102.5 ± 7.5 psi).

5. Adjust Tooling (E) in order to allow lubrication flow into the torque converter.

6. Record the value in Table 8.

Lube Circuit Check

1. Adjust the input rotation to 600 ± 10 rpm.

2. Shift the transmission into FORWARD 1.

3. Record the values of "P1", "P2", "P3", lubrication pressure, and lubrication flow in Table 9.

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

5. Adjust the input rotation to 2000 ± 10 rpm.

6. Shift the transmission into FORWARD 1.

7. Record the values of "P1", "P2", "P3", lubrication pressure, and lubrication flow in Table 10.

8. Shift the transmission through positions FORWARD 2, FORWARD 3, NEUTRAL, REVERSE 1, REVERSE 2, and REVERSE 3. Repeat Step 7.

9. Compare the recorded readings with the specifications.

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 11.

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

Specifications

Table 3

General Specifications
Description	Low Idle	High Idle
Input Speed	600 ± 10 rpm	2000 ± 10 rpm
Pump Capacity	26.49 ± 3.78 L/min (7 ± 1 US gpm)	75.70 ± 3.78 L/min (20 ± 1 US gpm)
Pressures
"P1" Initial	586.05 ± 34.47 kPa (85 ± 5 psi)
Priority Valve	1654.74 ± 68.94 kPa (240 ± 10 psi)
"P1"	1896.05 kPa (275 psi)	2102.90 ± 103.42 kPa (305 ± 15 psi)
"P2"	P1 − 344.74 ± 55.15 kPa (50 ± 8 psi)
"P3"	706.71 ± 51.71 kPa (102.5 ± 7.5 psi)
Lubrication Reference	13.79 kPa (2 psi) minimum	96.53 ± 27.58 kPa (14 ± 4 psi)

Transmission Bench Test Data Sheet

Table 4

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

Initial Pressure Check

Table 5

Initial Pressure

Input Speed (600 ± 10 rpm) Input Flow 26.49 ± 3.78 L/min (7 ± 1 US gpm)

kPa psi

Priority Valve Pressure Check

Table 6

Priority Valve Pressure

Input Speed (600 ± 10 rpm) Input Flow 26.49 ± 3.78 L/min (7 ± 1 US gpm)

kPa psi

Safety Valve Check

Table 7

Safety Valve Pressure		Input Speed (600 ± 10 rpm) Input Flow 26.4979 ± 3.7854 L/min (7 ± 1 US gpm)
"P1"	kPa psi	"P2"	kPa psi

Torque Converter Ratio Valve Check

Table 8

Torque Converter Ratio Valve Pressure

Input Speed (600 ± 10 rpm) Input Flow 26.49 ± 3.78 L/min (7 ± 1 US gpm)

kPa psi

Lube Circuit Check

Table 9

Low Idle Lube Circuit Check				Input Speed (600 ± 10 rpm) Input Flow 26.49 ± 3.78 L/min (7 ± 1 US gpm)
Gear Range	1F	2F	3F	N	1R	2R	3R
"P1"	______	______	______	______	______	______	______
"P2"	______	______	______	______	______	______	______
"P3"	______	______	______	______	______	______	______
Lube Pressure	______	______	______	______	______	______	______
Lube Flow	______	______	______	______	______	______	______
Average Lubrication Pressure of Arrangement				kPa psi

Table 10

High Idle Lube Circuit Check				Input Speed (2000 ± 10 rpm) Input Flow 75.71 ± 3.79 L/min (20 ± 1 US gpm)
Gear Range	1F	2F	3F	N	1R	2R	3R
"P1"	______	______	______	______	______	______	______
"P2"	______	______	______	______	______	______	______
"P3"	______	______	______	______	______	______	______
Lubrication Pressure	______	______	______	______	______	______	______
Lube Flow	______	______	______	______	______	______	______
Average Lubrication Pressure of Arrangement				kPa (psi)

Contamination Control

Table 11

ISO Particle Count

Sample the test bench oil supply. ISO 4406 is 16/13.

______/______ Particle Count

Table 12

______________________________________ Technician

______________________________________ Supervisor