Bench Test Procedure for a D6C, D6D, D6E, D6G, and D6G Series II Track-Type Tractor Transmission{3030, 3073} Caterpillar

Track-Type Tractor:

D6 (S/N: 76A1-UP)

D6C (S/N: 76A1-UP)

D6D (S/N: 5YB1-UP; 36C1-UP; 9FK1-UP; 75W1-UP; 03X1-UP; 04X1-UP; 06X1-UP; 20X1-UP; 31X1-UP; 32X1-UP; 33X1-UP)

D6E (S/N: 8FJ1-UP)

D6G Series 2 (S/N: C6G1-UP; P6G1-UP; BTJ1-UP; BWJ1-UP; 2MJ1-UP; C6X1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS3277
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 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, 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
D6C	7G-4245
D6D	7G-4245
D6E	7G-4245
D6G	7G-4245
D6G Series II	7G-4245

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, 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

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.

Table 3

Tooling	Tool Number	Part Description	Qty
A	FT-0669	Drive Adapter	1
B	7S-8743	Test Cover	1
C	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
D	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
E	FT-0702	Adapter	1
	7X-7646	Nipple (Quick Disconnect)	1
		Nipple (Close)	1
		Bushing	1
F	2M-5762	Flange Assembly	1
G	7S-8887	Nipple (Quick Disconnect)	1
	5P-3501	Adapter	1
	3J-1907	O-Ring Seal	1
H	2S-6436	Shipping Cover	1

FT Drawings

Illustration 3	g03871891
FT-0669 (A) 168.275 mm (6.625 inch) (B) 84.12 mm (3.312 inch) (C) 94.28 mm (3.712 inch) (D) 94.28 mm (3.712 inch) (E) Ø 6.4 ± 0.02 mm (0.252 ± 0.0008 inch) (F) 174.625 mm (6.875 inch) (G) 87.325 mm (3.438 inch) (H) 117.475 mm (4.625 inch) (J) 58.725 mm (2.312 inch) (K) Ø 13.45 mm (0.531 inch) 4 holes (L) 24.6 mm (0.969 inch) (M) 49.23 mm (1.938 inch) (N) 177.8 mm (7.0 inch) (P) 148.37 ± 0.01 mm (5.8415 ± 0.0005 inch) (Q) 114.3 mm (4.5 inch) (R) 70.37 ± 0.01 mm (2.7705 ± 0.0005 inch) (S) 42.875 mm (1.688 inch) (T) Ø 92.075 mm (3.625 inch) (U) Ø 10.31 mm (0.406 inch) (V) 90.07 ± 0.01 mm (3.546 ± 0.0005 inch) (W) Ø 8.2 mm (0.323 inch) (X) Ø 13.45 mm (0.531 inch) (Y) 209.51 ± 0.01 mm (8.2485 ± 0.0005 inch) (Z) 206.31 ± 0.01 mm (8.1225 ± 0.0005 inch)

Illustration 4	g03874379
FT-0702 (1) 2S-3643 Cover (2) 3B-6554 Elbow

Installation Procedure

1. Use the hoist to install the transmission on the test bench. The weight of the transmission is 459.94 kg (1014 lb).

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Illustration 5	g01310209

2. Install Tooling (A) .

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Illustration 6	g01309793
Typical example

3. Align the transmission with the input drive shaft.

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

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Illustration 7	g01309797
Typical example

5. Install the drive shaft guard.

6. Secure the transmission to the test bench to prevent movement during testing.

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Illustration 8	g01310198

7. Remove cover (1) from the top of the transmission.

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Illustration 9	g01310187

8. Remove plug (2) and plug (3) .

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Illustration 10	g01310181

9. Install Tooling (B) .

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Illustration 11	g01310178

10. Install Tooling (C) .

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Illustration 12	g01310175
Speed clutch pressure "P1" (4)

11. Connect pressure tap (4) to Tooling (C) .

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Illustration 13	g01310172

12. Install Tooling (D) .

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Illustration 14	g01309977
Directional clutch pressure and initial pressure "P2" (5)

13. Connect pressure tap (5) to Tooling (D) .

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Illustration 15	g01309970

14. Install Tooling (E) .

    Note: It may be necessary to chamfer the inside diameter of Tooling (E) to provide clearance with the sleeve in the transmission case.

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Illustration 16	g01309953

15. Connect hose (6) from the test bench to Tooling (E) .

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Illustration 17	g01309941

16. Install Tooling (F) .

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Illustration 18	g01309939

17. Connect hose (7) from the test bench to Tooling (F) .

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Illustration 19	g01309934

18. Remove plug (8) .

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Illustration 20	g01309925

19. Install Tooling (G) .

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Illustration 21	g01309910
Lubrication pressure (9)

20. Connect pressure tap (9) to Tooling (G) .

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Illustration 22	g01309863

21. Install Tooling (H) .

    Note: Several 25 mm (1 inch) holes should be drilled in the bottom of Tooling (H) 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, SENR7439, "D6D Tractor Power Train", Testing and Adjusting, SENR3930, "D6E Tractor Power Train", or Testing and Adjusting, KENR6346, "D6G 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 30 ± 4 L/min (8 ± 1 US gpm).

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Illustration 23	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 is determined as you face the drive motor of the test bench.

4. Shift the transmission through all directions and through all speed ranges to eliminate air from the transmission controls.

5. Lubrication pressure should be 23 ± 4 L/min (6 ± 1 US gpm).

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

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

7. Stop the input rotation.

8. Stop the input flow.

9. Record the value in Table 6.

Initial Pressure Check

1. Block the check valve open by placing a pin behind the valve.

2. Adjust the input flow to 30 ± 4 L/min (8 ± 1 US gpm).

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

4. Lubrication pressure should be 23 ± 4 L/min (6 ± 1 US gpm).

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

5. Initial "P2" pressure should be 296 ± 41 kPa (43 ± 6 psi).

6. Stop the input rotation.

7. Stop the input flow.

8. Remove the pin from behind the check valve to allow the valve to close.

9. Record the values in Table 7.

Safety Valve Check

1. Adjust the input flow to 30 ± 4 L/min (8 ± 1 US gpm).

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

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

4. Lube pressure should be 41± 7 kPa (6 ± 1 psi).

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

5. "P1" pressure should be 579 kPa (84 psi) and "P2" pressure should be 0 kPa (0 psi).

6. Shift the transmission into the NEUTRAL position.

7. "P1" pressure should be at least 2068 kPa (300 psi) and "P2" pressure should be P1 - 379 ± 55 kPa (55 ± 8 psi).

8. Stop the input rotation.

9. Stop the input flow.

10. Record the values in Table 8.

Lube Circuit Check

1. Adjust the input flow to 30 ± 4 L/min (8 ± 1 US gpm).

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

3. Shift the transmission into FORWARD 1.

4. Maintain "P1" pressure by using the relief valve on the test bench.

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

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

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

7. Shift the transmission into the FORWARD 1 position.

8. Adjust the input flow to 106 ± 4 L/min (28 ± 1 US gpm).

9. Adjust the input rotation to 1600 ± 10 rpm.

10. Maintain "P1" pressure by using the relief valve on the test bench.

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

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

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

13. Shift the transmission into the NEUTRAL position.

14. Stop the input rotation.

15. Stop the input flow.

16. Compare the recorded readings with the specifications in Table 10.

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.

Transmission Bench Test Data Sheet

Table 4

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

Specifications

Table 5

General Specifications
Description	Low Idle	High Idle
Input Speed	650 ± 10 rpm	1600 ± 10 rpm
Lube Flow (1)	30 ± 4 L/min (8 ± 1 US gpm)	106 ± 4 L/min (28 ± 1 US gpm)
Pressures
"P1"	2068 kPa (300 psi) minimum	2413 ± 69 kPa (350 ± 10 psi)
"P2" Initial	296 ± 41 kPa (43 ± 6 psi)	296 ± 41 kPa (43 ± 6 psi)
"P2"	P1 - 379 ± 55 kPa (55 ± 8 psi)	P1 - 379 ± 55 kPa (55 ± 8 psi)
Lube Reference	41 ± 7 kPa (6 ± 1 psi)	152 ± 21 kPa (22 ± 3 psi)

( 1 )

Maximum variation in lube flow between gear ranges must not exceed 5.678 L/min (1.5 US gpm).

Start Checks

Table 6

Lubrication Pressure

Input Speed (650 ± 10 rpm) Input Flow 30 ± 4 L/min (8 ± 1 US gpm)

_______kPa _______psi

Initial Pressure Check

Table 7

Initial Pressure		Input Speed (650 ± 10 rpm)
		Input Flow 30 ± 4 L/min (8 ± 1 US gpm)
"P2"		_______kPa _______psi

Safety Valve Check

Table 8

Safety Valve Pressure		Input Speed (650 ± 10 rpm)
		Input Flow 30 ± 4 L/min (8 ± 1 US gpm)
"P1"	_______kPa _______psi	"P2"	_______kPa _______psi

Lube Circuit Check

Table 9

Low Idle Lube Circuit Check				Input Speed (650 ± 10 rpm)
				Input Flow 30 ± 4 L/min (8 ± 1 US gpm)
Gear Range	1F	2F	3F	N	1R	2R	3R
"P1"	______	______	______	______	______	______	______
"P2"	______	______	______	______	______	______	______
Lubrication Pressure	______	______	______	______	______	______	______
Lube Flow	______	______	______	______	______	______	______
Average Lubrication Pressure of Arrangement				_______kPa _______psi

Table 10

High Idle Lube Circuit Check				Input Speed (1600 ± 10 rpm)
				Input Flow 106 ± 4 L/min (28 ± 1 US gpm)
Gear Range	1F	2F	3F	N	1R	2R	3R
"P1"	______	______	______	______	______	______	______
"P2"	______	______	______	______	______	______	______
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