Bench Test Procedure for D6R and D7R Track-Type Tractor Transmission{3030, 3073} Caterpillar

Track-Type Tractor:

D6R (S/N: EMM1-UP; JEN1-UP; S6T1-UP; S6X1-UP; S6Y1-UP)

D7R (S/N: R7B1-UP; R7C1-UP; DSH1-UP; R7H1-UP; DLN1-UP; DJR1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS3607
04	Added new serial number prefixes.
03	Added serial number prefixes. Updated introduction.
02	Added new introduction, Canceled Part Numbers section, serial numbers, transmission arrangement, and updated graphics.

© 2014 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 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 issue, use the following resources in order 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
D6R	315-9959
D7R	315-9963

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.

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 often used in order 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.

Illustration 1	g02139237

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.

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 in order to develop this test procedure.

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9586	Swivel Head Support Gp	1
	1U-9584	Rail As	2
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	138-7575	Link Bracket	2
	0L-1329	Bolt (1/2-13X3 inch)	2
	4B-5273	Washer	2
	1D-4719	Full Nut	2
	1U-9722	Load Binder As (Ratchet Type)	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	6V-3965	Nipple Assembly (Valve)	2
	3J-1907	O-Ring	2
K	2M-2829	Control Lever	1
	0L-1170	Handle	1
	9H-6673	Pin	1
	6S-6646	Lock Pin	1
L	4M-7307	Control Lever	1
	0L-1170	Handle	1
	9H-6673	Pin	1
	6S-6646	Lock Pin	1
M (2)	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	3
	6V-4144	Coupler	3
N (1)	8T-0854	Pressure Gauge (0 to 400 kPa (0 to 140 psi))	3
	6V-4144	Coupler	3
P (1)	4C-9910	Portable Hydraulic Tester	2

( 1 )	The yoke assemblies are interchangeable. The yoke may be removed from the main drive shaft in order to be used during the test.
( 2 )	Optional Tooling if needed with Test Bench

Installation Procedure

Show/hide table



Illustration 2	g02156396

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

   Note: Use the existing transmission bolts.

Show/hide table



Illustration 3	g02156401

2. Use a hoist to install the transmission on the test bench. The weight of the transmission is 862 kg (1900 lb).

Show/hide table



Illustration 4	g02156403

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

Show/hide table



Illustration 5	g02156407

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

Show/hide table



Illustration 6	g02156408

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

Show/hide table



Illustration 7	g02156410

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

Show/hide table



Illustration 8	g02156413

7. Align the transmission to the input drive shaft.

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

Show/hide table



Illustration 9	g02156415

9. Install the drive shaft guard.

Show/hide table



Illustration 10	g02156417

Show/hide table



Illustration 11	g02723286

10. Install Tooling (F) to the transmission to prevent movement during testing.

11. Tighten all four jack bolts and castle nuts on test bench bed.

Show/hide table



Illustration 12	g02723297

12. Install Tooling (G) to the transmission case.

Show/hide table



Illustration 13	g02723304

13. Install Tooling (H) onto Tooling (G)

Show/hide table



Illustration 14	g02173034
Main Pump Supply

14. Connect hose assembly (1) from the pressurized flow meter to Tooling (G) .

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

Show/hide table



Illustration 15	g02173053
Torque Converter (out)

15. Connect hose assembly (2) 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.

Show/hide table



Illustration 16	g03744216
Lube (in)

16. Connect hose assembly (3) from the No. 2 flow meter (out) to Tooling (G) .

Show/hide table



Illustration 17	g03744222
(4) Priority Valve (5) Torque Converter (in) pressure "P3" (6) Transmission lube pressure

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

17. Connect pressure gauge (4) to Tooling (G) .

18. Connect pressure gauge (5) to Tooling (G) .

19. Connect pressure gauge (6) to Tooling (G) .

Show/hide table



Illustration 18	g02156431

20. Remove cover plate (7) .

Show/hide table



Illustration 19	g02723314

21. Install Tooling (J), as shown.

Show/hide table



Illustration 20	g02156435

22. Remove cover (8) .

Show/hide table



Illustration 21	g02156438
Direction Selector

23. Install Tooling (K) .

Show/hide table



Illustration 22	g02156439
Speed Selector

24. Install Tooling (L) .

25. Install cover (8) .

Show/hide table



Illustration 23	g02156465
(9) "P2" Speed Clutch Pressure (10) "P1" Direction Clutch Pressure

26. Connect pressure gauge (9) to Tooling (J) .

27. Connect pressure gauge (10) to Tooling (J) .

Show/hide table



Illustration 24	g02723316

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

Test Procedure

Start Checks

Note: Refer to Testing and Adjusting, KENR8564, "D6R 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 55 ± 2 L/min (14.6 ± 0.5 US gpm).

Show/hide table



Illustration 25	g02720621

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. 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.

Show/hide table



Illustration 26	g01091561

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

5. Stop the input rotation.

Initial Pressure Check

Show/hide table



Illustration 27	g02723332
Top View

1. Remove the load piston plug from the top of the transmission control valve. The plug will be accessed through the top of the transmision case.

2. Adjust the input flow to 55 ± 2 L/min (14.6 ± 0.5 US gpm).

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 800 ± 30 rpm.

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

5. Record the value in Table 6.

6. The pressure for the priority valve must be 2551 ± 138 kPa (370 ± 20 psi). This pressure is measured at pressure tap (4) .

7. Record the value in Table 6.

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 55 ± 2L/min (14.6 ± 0.5 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 800 ± 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 (5) .

6. Open Tooling (H) .

7. Record the value in Table 7.

Valve Check (Pressure Differential)

1. Shift the transmission to the FORWARD 3.

2. Adjust the input flow to 55 ± 2 L/min (14.6 ± 0.5 US gpm).

3. Adjust the input rotation to 800 ± 30 rpm. The "P2" pressure must be 0 kPa (0 psi).

4. Increase the input flow to 131 ± 1 L/min (34.7 ± 0.25 US gpm) .

5. Increase the input rotation to 2110 ± 30 rpm. The "P2" pressure must remain at 0 kPa (0 psi).

6. Adjust the input rotation to 800 ± 30 rpm.

7. Shift the transmission to NEUTRAL and then shift the transmission to FORWARD 3.

8. Adjust the input rotation to 2110 ± 30 rpm. The "P2" pressure must rise to normal pressure.

9. Record the value in Table 8.

10. Adjust the input rotation to 800 ± 30 rpm.

11. Shift the transmission to NEUTRAL.

Lube Circuit Check

1. Adjust the input flow until the lube flow is 76 ± 0.8 L/min (20.0 ± 0.2 US gpm).

2. Adjust the input rotation to 800 ± 30 rpm.

3. Shift the transmission to FORWARD 2.

4. The lube pressure must be within ± 14 kPa (± 2 psi) of the average for this transmission arrangement. Reference is 158 ± 14 kPa (22.9 ± 2.0 psi).

5. Record the value in Table 9.

Clutch Leakage Check

1. Adjust the input flow to 131 ± 1 L/min (34.7 ± 0.25 US gpm). Maintain this flow during this check.

2. Adjust the input rotation to 800 ± 30 rpm in the NEUTRAL position.

3. Shift the transmission to FORWARD 1.

4. Adjust the input rotation to 2110 ± 30 rpm in the FORWARD 1 position.

5. Record the input flow in Table 10.

6. Record the output flow in Table 10.

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

8. Record the calculation in Table 10.

9. Adjust the input rotation to 800 ± 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.

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 6 ± 3 L/min (1.5 ± 0.8 US gpm)

Specifications

Table 4

General Specifications
Description	High Idle	Low Idle
Input Speed	2110± 30 rpm	800 ± 30 rpm
Input Flow	131 ± 1 L/min (34.7 ± 0.25 US gpm)	55 ± 2 L/min (14.6 ± 0.5 US gpm)
Minimum Lube Flow	98 L/min (26 US gpm)	37 L/min (9.9 US gpm)
Pressures
"P1" Initial (1)		531 ± 34 kPa (77 ± 5 psi)
Priority Valve (1)		2551 ± 138 kPa (370 ± 20 psi)
P1	2482 ± 138 kPa (360 ± 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	393 ± 48 kPa (57 ± 7 psi)	19 kPa (2.8 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.

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 5

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

Initial Pressure Check

Table 6

Initial Pressure

Input Speed (800 ± 30 rpm) Input Flow 55 ± 2 L/min (14.6 ± 0.5 US gpm)

kPa (psi)

Torque Converter Inlet Ratio Valve Check

Table 7

Torque Converter Inlet Ratio Valve Pressure

Input Speed (800 ± 30 rpm) Input Flow 55 ± 2 L/min (14.6 ± 0.5 US gpm)

kPa (psi)

Valve Check (Pressure Differential)

Table 8

Valve Check (Pressure Differential)
Input Flow	Input Speed	Gear Range	"P2" Pressure
55 ± 2 L/min (14.6 ± 0.5 US gpm)	800 ± 30 rpm	FORWARD 3	kPa (psi)
131 ± 1 L/min (34.7 ± 0.25 US gpm)	2110 ± 30 rpm	FORWARD 3	kPa (psi)

Lube Circuit Check

Table 9

Lube Circuit Check		Gear Range FORWARD 2 Input Speed (800 ± 30 rpm) Lube Flow 76 ± 0.8 L/min (20.0 ± 0.2 US gpm)
Average Lube Pressure Of Arrangement	kPa (psi)	Lube Pressure	kPa (psi)

Clutch Leakage Check

Table 10

Clutch Leakage Check		Input Speed (1800 ± 30 rpm) Input Flow 2.3 L/min (0.6 US gpm)
Gear Range	1F	2F	3F	1R	2R	3R	N
Input Flow	______	______	______	______	______	______	______
Output Flow	______	______	______	______	______	______	______
Leakage	______	______	______	______	______	______	______
Average of Arrangement	______	______	______	______	______	______	______

Contamination Control

Table 11

Contamination Control

Sample the test bench oil supply.

________/________Particle Count

Table 12

______________________________________ Technician

______________________________________ Supervisor