Bench Test Procedure for a D5 and D5B Track-Type Tractor Transmission {3030, 3073} Caterpillar

Track-Type Tractor

D5 (S/N: 95J1-UP; 96J1-UP)

D5B (S/N: 8HD1-UP; 24X1-UP; 25X1-UP; 44X1-UP; 48X1-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-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

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 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

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.

FT-Drawings

Illustration 3	g03889194
FT-0668 (A) 114.3 mm (4.5 in) (B) 57.15 mm (2.25 in) (C) 24.6 mm (0.969 in) (D) 117.5 mm (4.625 in) (E) 58.7 mm (2.312 in) (F) 21.4 mm (0.844 in) (G) 70.36 ± 0.01 mm (2.77 ± 0.0005 in) (H) 35.2 mm (1.385 in) (J) 45.0 mm (1.773 in) (K) 90.07 ± 0.01 mm (3.546 ± 0.0005 in) (L) Ø 92.075 mm (3.625 in) (M) 49.2 mm (1.938 in) (N) Ø 13.49 mm (0.531 in) (O) Ø 5.94 mm (0.234 in) (P) 42.9 mm (1.688 in) (Q) Ø 10.3 mm (0.406 in) (R) 25.4 mm (1.0 in) (S) 6.35 mm (0.25 in) (T) Ø 140.45 ± 0.01 mm (5.5295 ± 0.0005 in) (U) Ø 148.37 ± 0.01 mm (5.8415 ± 0.0005 in)

Illustration 4	g03871891
FT-0669 (A) 168.275 mm (6.625 in) (B) 84.12 mm (3.312 in) (C) 94.28 mm (3.712 in) (D) 94.28 mm (3.712 in) (E) Ø 6.4 ± 0.02 mm (0.252 ± 0.0008 in) (F) 174.625 mm (6.875 in) (G) 87.325 mm (3.438 in) (H) 117.475 mm (4.625 in) (J) 58.725 mm (2.312 in) (K) Ø 13.45 mm (0.531 in) 4 holes (L) 24.6 mm (0.969 in) (M) 49.23 mm (1.938 in) (N) 177.8 mm (7.0 in) (P) 148.37 ± 0.01 mm (5.8415 ± 0.0005 in) (Q) 114.3 mm (4.5 in) (R) 70.37 ± 0.01 mm (2.7705 ± 0.0005 in) (S) 42.875 mm (1.688 in) (T) Ø 92.075 mm (3.625 in) (U) Ø 10.31 mm (0.406 in) (V) 90.07 ± 0.01 mm (3.546 ± 0.0005 in) (W) Ø 8.2 mm (0.323 in) (X) Ø 13.45 mm (0.531 in) (Y) 209.51 ± 0.01 mm (8.2485 ± 0.0005 in) (Z) 206.31 ± 0.01 mm (8.1225 ± 0.0005 in)

Illustration 5	g06065720
FT-0715

Installation Procedure

1. Use a hoist to install the transmission on the test bench. The weight of the transmission is 605 kg (1334 lb).
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   Illustration 6	g01308943

2. Install Tooling (A).
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   Illustration 7	g01308944
   Typical example

3. Align the transmission to the input drive shaft.

4. Connect the input drive shaft to Tooling (A).
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   Illustration 8	g01308946
   Typical example

5. Install the drive shaft guard.
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   Illustration 9	g01308949

6. Install Tooling (B).
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   Illustration 10	g01308952

7. Connect suction hose (1) from Tooling (B) to the test bench.
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   Illustration 11	g01308953

8. Install Tooling (C).
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   Illustration 12	g01308955

9. Install Tooling (D) on Tooling (C).
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   Illustration 13	g01308957

10. Connect hose (2) from Tooling (D) to the No. 2 flow meter inlet.
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    Illustration 14	g01308959

11. Remove plug (3).
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    Illustration 15	g01308963

12. Install Tooling (E).
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    Illustration 16	g01308964
    (4) Torque converter Outlet Pressure

13. Connect pressure tap (4) to Tooling (E).
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    Illustration 17	g01309337

14. Remove plug (5).
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    Illustration 18	g01309318

15. Install Tooling (F).
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    Illustration 19	g01309315
    (6) Torque Converter Inlet Pressure

16. Connect pressure tap (6) to Tooling (F).
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    Illustration 20	g01309309

17. Remove plug (7).
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    Illustration 21	g01309305

18. Install Tooling (G).
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    Illustration 22	g01309300

19. Connect pressure tap (8) to Tooling (G).
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    Illustration 23	g01309292

20. Install Tooling (H).
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    Illustration 24	g01309277

21. Connect hose (9) from the No. 2 flow meter outlet to Tooling (H).
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    Illustration 25	g01309234

22. Remove cover (10) from the top of the transmission.
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    Illustration 26	g01309227

23. Remove plug (11) and plug (12).
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    Illustration 27	g01309217

24. Install Tooling (J).
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    Illustration 28	g01309201

25. Install Tooling (K).
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    Illustration 29	g01309193

26. Install Tooling (L).
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    Illustration 30	g01309187
    (13) Speed Clutch Pressure "P1"

27. Connect pressure tap (13) to Tooling (J).
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    Illustration 31	g01309127
    (14) Directional Clutch Pressure "P2"

28. Connect pressure tap (14) to Tooling (K).
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    Illustration 32	g06086526

29. Install Tooling (M).

    Note: Several 25.4 mm (1 inch) holes should be drilled in the bottom of Tooling (M) to allow oil to drain from the transmission.

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

Test Procedure

Start Checks

Note: Refer to Testing and Adjusting, REGO0660, "D5 Tractor Power Train" or Testing and Adjusting, SENR7555, "D5B 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 25 ± 8 L/min (7 ± 2 US gpm).
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   Illustration 33	g02720621

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 650 ± 10 rpm.

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

4. The lubrication pressure must be 41 ± 14 kPa (6 ± 2 psi).

   Note: If there is no lube pressure after 30 seconds, stop input rotation and check connections on test bench and transmission.

5. Record the reading in Table 7.

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

7. 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

8. Check for lockup or excessive drag in all directions and in all gears.

9. Stop the input rotation.

10. Stop the input flow.

Initial Pressure Check

1. Adjust the input flow to 25 ± 8 L/min (7 ± 2 US gpm).

2. Adjust the input rotation to 650 ± 10 rpm.

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

4. Initial "P1" pressure must be at least 607 kPa (88 psi) and "P2" pressure must be 0 kPa (0 psi).

5. Record the values in Table 8.

Safety Valve Check

1. Adjust the input flow to 25 ± 8 L/min (7 ± 2 US gpm).

2. Adjust the input rotation to 650 ± 10 rpm.

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

4. Shift the transmission back into the NEUTRAL position.

5. "P1" pressure must be at least 2275 kPa (330 psi) and "P2" pressure must be P1 - 379 ± 55 kPa (55 ± 8 psi).

6. Record the values in Table 9.

Torque Converter Inlet Valve Check

1. Adjust the input flow to 25 ± 8 L/min (7 ± 2 US gpm).

2. Adjust the input rotation to 650 ± 10 rpm.

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

4. Adjust Tooling (D) to temporarily block lubrication flow to the torque converter.

5. "P3" pressure must be 931 ± 69 kPa (135 ± 10 psi).

6. Adjust Tooling (D) to allow lubrication flow into the torque converter.

7. Record the value in Table 10.

Lube Circuit Check

1. Adjust the input flow to 25 ± 8 L/min (7 ± 2 US gpm).

2. Adjust the input rotation to 650 ± 10 rpm.

3. Shift the transmission into FORWARD 1.

4. Record the values of "P1", "P2", "P3", torque converter outlet pressure, lubrication pressure, and lubrication flow in Table 11.

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

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

6. Shift the transmission into FORWARD 1.

7. Adjust the input flow to 62.5 ± 8 L/min (16.5 ± 2 US gpm).

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

9. Record the values of "P1", "P2", "P3", torque converter outlet pressure, lubrication pressure, and lubrication flow in Table 12.

10. Adjust the input rotation to 650 ± 10 rpm.

11. Shift the transmission through positions FORWARD 2, FORWARD 3, NEUTRAL, REVERSE 1, REVERSE 2, and REVERSE 3. Repeat Step 8 through 10 for each gear range.

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

12. Compare the recorded readings with the specifications in Table 6.

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 13.

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

Transmission Bench Test Data Sheet

Specifications

Preliminary Checks

Initial Pressure Check

Safety Valve Check

Torque Converter Inlet Valve Check

Lube Circuit Check

Contamination Control