Bench Test Procedure for a D6T and D6R Track-Type Tractor and PL72 Pipelayer Transmission{3030, 3073} Caterpillar


Bench Test Procedure for a D6T and D6R Track-Type Tractor and PL72 Pipelayer Transmission{3030, 3073}

Usage:

D6T XW CG8
Pipelayer:
PL72 (S/N: P721-UP; P731-UP)
Track-Type Tractor:
D6R Series 2 (S/N: PPP1-UP; SSS1-UP; TTT1-UP)
D6T (S/N: SGA1-UP; JHB1-UP; KSB1-UP; ZJB1-UP; JZC1-UP; SMC1-UP; DTD1-UP; LBD1-UP; RAD1-UP; LAE1-UP; STE1-UP; DJG1-UP; WCG1-UP; WFH1-UP; EJJ1-UP; LKJ1-UP; SLJ1-UP; GMK1-UP; RRK1-UP; KJL1-UP; MEL1-UP; SKL1-UP; TSM1-UP; WLM1-UP; WRN1-UP; KMR1-UP; PLR1-UP; WES1-UP; GCT1-UP; SGT1-UP; JRW1-UP; RCW1-UP; LAY1-UP; TMY1-UP; HTZ1-UP; PEZ1-UP; CR31-UP; CG81-UP)

Introduction

Table 1
Revision     Summary of Changes in REHS3610    
06     Added new serial number prefix.
Updated Table 2.    
05     Added new serial number prefixes.
Added new transmission arrangement to Table 2.
Updated Title.
Standardized.    
04     Added new serial number prefixes.    
03     Added new serial number prefixes.
Updated Introduction.
Added new transmission arrangement to Table 2.    

© 2015 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar 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 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 need, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

  • Cat Dealer Techinical Communicator

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  • Cat Technical Representative

  • Knowledge Network

Table 2
Machine Model     Transmission Arrangement    
D6T     384-4139, 220-1429, 354-0148    
D6R     417-8818, 417-8819    
PL72     354-0148    

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 1g02139237

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 2g00008666

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.

------ WARNING! ------

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.

----------------------

------ WARNING! ------

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

----------------------

------ WARNING! ------

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

Table 3
Required Tools    
Tool     Part Number     Part Description     Qty    
A     1U-9584     Rail As     2    
1U-9585 Mounting Block Gp     1    
1U-9586 Swivel Head Support Gp     1    
B     138-7575     Link Bracket     3    
0L-1329 Bolt (1/2-13X3 inch)     2    
4B-5273 Washer     2    
1D-4719 Full Nut     2    
1U-9722 Ratcheting Turnbuckle     3    
(1)     3T-8305     Yoke As     1    
9G-1930 Yoke As     1    
D     FT-1665     Drive Adapter     1    
0L-0478 Bolt (3/8-24X1.75 inch)     4    
3B-4506 Lockwasher     4    
E     136-3647     Drive Adapter As     1    
0S-1594 Bolt (3/8-16X1 inch)     4    
3B-4506 Lockwasher     4    
F     1U-9131     Drive Adapter (Key)     1    
G     1U-7044     Lube Adapter     1    
8C-9024 Nipple Assembly (Plain)     1    
6V-3966 Nipple Assembly (Valve)     3    
Plug Plug (1-11 1/2 NPTF inch)     1    
7X-0341 Bolt (1/2-13X7 inch)     2    
8T-4223 Hard Washer     4    
6V-8188 Nut     2    
H     8C-9024     Nipple Assembly (Plain)     1    
3T-9549 Adapter     1    
5P-0492 Adapter     1    
J     175-2599     Plug (Expandable)     1    
K     8T-0855     Pressure Gauge (0 TO 4,000-KPA (0 TO 580-PSI))     6    
6V-4144 Quick Connect Coupler     6    
L     8T-0854     Pressure Gauge (0 TO 965-KPA (0 TO 140-PSI))     1    
6V-4144 Quick Connect Coupler     1    
M     453-4703 (2)     Adapter Harness As     1    
306-0397 (2) Extension Cable     1    
256-7623 Test Cable As     1    
9U-7498 Extension Cable     1    
300-4993 Adapter Cable As     1    
N     277-2362     Transmission Analyzer III Gp     1    
P     146-4080     Digital Multimeter     1    
R     364-6747     Manifold     1    
8C-9024 Nipple Assembly (Plain)     1    
3H-5932 Bolt     4    
9M-1974 Washer     4    
( 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 ) Use for Tier 4 Final only

FT Drawings




Illustration 3g03823820

FT-1665

(A) 44.45 mm (1.75 inch)

(B) 12.7 mm (0.5 inch)

(C) 31.75 mm (1.25 inch)

(D) Ø 149.23 mm (5.875 inch)

(E) Ø 140.45 mm (5.53 inch)

(F) 94.28 mm (3.71 inch)

(G) 47.14 mm (1.86 inch)

(H) 94.28 mm (3.71 inch)

(I) 47.14 mm (1.86 inch)

(J) 42.88 mm (1.69 inch)

(K) 21.44 mm (0.844 inch)

(L) Ø 8.2 mm (0.3 inch), 25.4 mm (1.0 inch) Deep, 3/8-12-2B THD

(M) Ø 10.5 mm (0.4 inch), Ø 22.2 mm (0.874 inch) Bore, 14 mm (0.55 inch) Deep

(N) Ø 92.0 mm (3.622 inch)

(O) 57.15 mm (2.25 inch)

(P) 114.3 mm (4.5 inch)

Installation Procedure




    Illustration 4g01457282

  1. Install Tooling (A) on the test bench, as shown.



    Illustration 5g01465949



    Illustration 6g02336596

  1. Install Tooling (B) to lift the transmission.



    Illustration 7g01457425

  1. Remove Brackets (1) .



    Illustration 8g01457650



    Illustration 9g02344516

  1. Remove Cover Plate (2) and the Filter Screen (2) .



    Illustration 10g01457263

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

    Note: Use the transmission bolts that were removed in step 3.




    Illustration 11g02337299

  1. Use a hoist to install the transmission on the test bench. The weight of the transmission is 907 kg (2000 lb).



    Illustration 12g01457464

  1. Install Tooling (B) to the transmission to prevent movement of the transmission.

    Note: Over-tightening Tooling (B) can jeopardize the tightening ability of the castle nuts on Tooling (A) later in this section.




    Illustration 13g01457442

  1. Install Tooling (C) on the Input Shaft.



    Illustration 14g01457478

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



    Illustration 15g01457503

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



    Illustration 16g01457508

  1. Install Tooling (F) on Tooling (E) .



    Illustration 17g01457519

  1. Align the transmission to the input drive shaft.

  1. Connect the input drive shaft to Tooling (F) .



    Illustration 18g01457528

  1. Install the drive shaft guard.



    Illustration 19g03802221

  1. Tighten all four castle nuts and jack bolts.

  1. Tighten Tooling (B) to prevent movement of the transmission during testing.



    Illustration 20g02337738

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

    Note: The center port is blocked internally.




    Illustration 21g02349860

  1. Remove Plug (3) .



    Illustration 22g02339557

  1. Install Tooling (H) .



    Illustration 23g02342888

  1. Remove cover (4) .



    Illustration 24g02342936

  1. Remove main relief valve (5) .



    Illustration 25g02342981

  1. Install tooling (R) under main relief valve. Torque bolts to 24 N·m (18 lb ft).



    Illustration 26g03825998

    Controls (in)

  1. Connect Hose Assembly (6) from the pressurized flow meter to Tooling (G) .



    Illustration 27g03826008

    Controls (out)

  1. Connect Hose Assembly (7) from Tooling (R) to the inlet of the No. 2 flow meter.



    Illustration 28g02339656

    (8) Transmission Lubrication Supply

  1. Connect Hose Assembly (8) from the outlet of the No. 2 flow meter to Tooling (G) .



    Illustration 29g02342767

    (9) Supply Pressure 0 - 4000 kPa (0 - 580 psi)

    (10) Lubrication Oil Pressure 0 - 965 kPa (0 - 140 psi)

  1. Install Pressure Gauge (9) and (10) .



    Illustration 30g02342856

    0 - 4000 kPa (0 - 580 psi)

    (11) Pressure tap for the No. 5 clutch

    (12) Pressure tap for the No. 4 clutch

    (13) Pressure tap for the No. 3 clutch

    (14) Pressure tap for the No. 2 clutch

    (15) Pressure tap for the No. 1 clutch

  1. Install Pressure Gauges (11), (12), (13), (14) and (15) .



    Illustration 31g02343957

  1. Connect Tooling (M) to the transmission.



    Illustration 32g02343996

  1. Connect Ground Clamp (16) to a suitable area.



    Illustration 33g02629190

    Tooling (N)

  1. Connect Tooling (M) to Tooling (N). Connect Tooling (N) to a power source. Refer to Tool Operating Manual, NEHS0966 for the correct operating instructions.



    Illustration 34g01457863

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

Test Procedure

Harness Test

  1. Make sure that Tooling (M) is properly connected.

  1. Use Tooling (N) to perform the harness test.

  1. Record the values in Table 6.

Start Checks

    Note: Refer to Testing and Adjusting, RENR7957, "D6R Series III Track-Type Tractor Power Train" or Testing and Adjusting, KENR5124, "D6T Track-Type 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.

  1. Adjust the Input Flow to 53 ± 3.8 L/min (14 ± 1 US gpm).

  1. Check the Supply Pressure. The correct Supply Pressure is 2792 ± 69 kPa (405 ± 10 psi).



    Illustration 35g02720621

  1. 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.

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

  1. Shift the transmission until all clutch fills are consistent.

  1. Verify correct clutch engagement with Table 4.

    Table 4
    Clutch Engagement    
    Gear     Clutch 1     Clutch 2     Clutch 3     Clutch 4     Clutch 5    
    F1         X             X    
    F2         X         X        
    F3         X     X            
    R1     X                 X    
    R2     X             X        
    R3     X         X            

  1. The Lubrication Oil Pressure must be between 47 kPa (6 psi) and 63 kPa (9 psi).

  1. Record the value in Table 7.

Lubrication Circuit

  1. Adjust the Lubrication Oil Flow to 76 ± 4 L/min (20 ± 1 US gpm).

  1. Adjust the Input Rotation to 700 ± 30 rpm.

  1. Shift the transmission to FORWARD 2.

  1. Adjust the Input Rotation to 1900 ± 30 rpm.

  1. The Lubrication Oil Pressure must be within 14 kPa (2 psi) of the average of this arrangement. The reference is110 ± 14 kPa (16 ± 2 psi).

  1. Record the value in Table 8.

Clutch Leakage Check

  1. Adjust the Input Flow to 98 ± 3.8 L/min (26 ± 1 US gpm). Maintain this flow during this check.

  1. Adjust the Input Rotation to 1900 ± 30 rpm in the NEUTRAL position.

  1. Check the Supply Pressure. The correct Supply Pressure is 2896 ± 205 kPa (420 ± 30 psi).

  1. Adjust the Input Rotation to 700 ± 30 rpm.

  1. Shift the transmission to FORWARD 1.

  1. Adjust the Input Rotation to 1900 ± 30 rpm.

  1. Record the Input Flow in Table 9.

  1. Record the Output Flow in Table 9.

  1. The leakage is obtained by subtracting the Output Flow from the Input Flow.

  1. Record the calculation in Table 9.

  1. Adjust the Input Rotation to 700 ± 30 rpm.

  1. Shift the transmission through positions FORWARD 2, FORWARD 3, NEUTRAL, REVERSE 1, REVERSE 2, REVERSE 3. Repeat Steps 6 through 11 for each gear range.

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

  1. The difference in leakage of SECOND gear and THIRD gear should not exceed 2.3 L/min (0.6 US gpm).

  1. The leakage of FIRST gear must not exceed 5.4 ± 3.0 L/min (1.4 ± 0.8 US gpm) of the average leakage of all other gears.

Speed Sensor Test

    Note: This transmission arrangement has two output speed sensors that must be tested.

  1. Adjust the Input Flow to 53 ± 3.8 L/min (14 ± 1 US gpm).

  1. Adjust the Input Rotation to 700 ± 5 rpm.

  1. Shift the transmission to FORWARD 1.



    Illustration 36g01457859

  1. Use Tooling (P) to measure the sensor signal voltage. Measure each output speed sensor.

  1. Record the values in Table 10.

  1. The voltage must be between 1.1 VRMS and 4.6 VRMS.

  1. Verify that both output speed sensors continue to have output.

  1. Record the values in Table 10.

Transmission Bench Test Data Sheet

Table 5
CATERPILLAR     Transmission Bench Test Data Sheet     Test Date:__________    
Model:__________
Work Order:__________     Serial No.:__________    

Harness Test

Table 6
Solenoid Test     Solenoid 1     Solenoid 2     Solenoid 3     Solenoid 4     Solenoid 5    

________ ohms

________ ohms    

________ ohms    

________ ohms    

________ ohms    

Start Checks

Table 7
Lubrication Oil Pressure     Input Speed (700 ± 30 rpm)
Input Flow
53 ± 3.8 L/min (14 ± 1 US gpm)
Supply Pressure
2792 ± 69 kPa (405 ± 10 psi)    
__________kPa
__________(psi)    

Lubrication Circuit

Table 8
Lubrication Circuit Check     Gear Range FORWARD 2
Input Speed (1900 ± 30 rpm)
Lubrication Flow
76 ± 3.8 L/min (20 ± 1 US gpm)    
Average Lubrication Oil Pressure Of Arrangement     __________kPa
__________(psi)    
Lubrication Oil Pressure     __________kPa
__________(psi)    

Clutch Leakage Check

Table 9
Clutch Leakage Check     Input Speed (1900 ± 30 rpm)
Input Flow
98 ± 3.8 L/min (26 ± 1 US gpm)
Supply Pressure
2896 ± 205 kPa (420 ± 30 psi)    
Gear Range     1F     2F     3F     1R     2R     3R     N    

Input Flow    
______     ______     ______     ______     ______     ______     ______    

Output Flow    
______     ______     ______     ______     ______     ______     ______    

Leakage    
______     ______     ______     ______     ______     ______     ______    
Average of Arrangement     ______     ______     ______     ______     ______     ______     ______    

Speed Sensor Test

Table 10
Speed Sensor Test     Input Speed (700 ± 5 rpm)
Input Flow
53 ± 3.8 L/min (14 ± 1 US gpm)
Supply Pressure
2792 ± 69 kPa (405 ± 10 psi)    
Sensor     Gear Range    
FORWARD 1 FORWARD 2    

Output Speed Sensor 1    
__________________ VRMS     __________________ VRMS    

Output Speed Sensor 2    
__________________ VRMS     __________________VRMS    

ISO Particle Count

Table 11
ISO Particle Count     Sample the test bench oil supply.
   
________/________Particle Count    

Table 12






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