Bench Test Procedure for a D5R, D5T, and D6N Track-Type Tractor Transmission with Differential Steering {3030, 3073, 3139} Caterpillar

Track-Type Tractor

D5R (S/N: D5L1-UP; D5X1-UP)

D5R2 (S/N: R5A1-UP; WRE1-UP; WDZ1-UP)

D6N (S/N: SC61-UP; PBA1-UP; PER1-UP; P5S1-UP; P5T1-UP; P5W1-UP)

Introduction

© 2017 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. 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 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 technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

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

Installation Procedure

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Illustration 3	g02681282

1. Install Tooling (A) to the input end of the transmission, as shown.
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   Illustration 4	g03863936

2. Install Tooling (A) to the rear of the transmission, as shown.
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   Illustration 5	g02681556

3. Use a hoist to install the transmission on the test bench. The weight of the transmission is 510 kg (1125 lb).
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   Illustration 6	g02681569

4. Install Tooling (B) on the input shaft.
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   Illustration 7	g02681578

5. Install Tooling (C) on Tooling (B).
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   Illustration 8	g02681616

6. Install Tooling (D) on Tooling (C).
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   Illustration 9	g02681623

7. Install Tooling (E) on Tooling (D).
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   Illustration 10	g02681676

8. Align the transmission to the input drive shaft.

9. Connect the input drive shaft to Tooling (E).
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   Illustration 11	g02681816

10. Install the drive shaft guard.
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    Illustration 12	g03375318

11. Tighten all four castle nuts and jack bolts.
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    Illustration 13	g02681838

12. Install Tooling (F).

    Note: Install the longest bolt in the lower hole location. Use the lower bolt to attach Tooling (G).

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    Illustration 14	g02681936

13. Install Tooling (G) to the rear of the transmission to prevent movement during testing.
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    Illustration 15	g02681979

14. Install Tooling (G) to the input end of the transmission to prevent movement during testing.
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    Illustration 16	g02682039

15. Install Tooling (H) on the transmission case.
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    Illustration 17	g02682056

16. Remove two plugs (1).
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    Illustration 18	g02682096

17. Install Tooling (J).
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    Illustration 19	g03863941

18. Install Tooling (K).

19. Remove dust cover from existing Quick Disconnect (2).
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    Illustration 20	g02682317

20. Connect hose assembly (3) from the pressurized flow meter to Tooling (F).

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

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    Illustration 21	g02682336

21. Connect hose assembly (4) from Tooling (J) 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.

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    Illustration 22	g02682339
    Lube (in)

22. Connect hose assembly (5) from the No. 2 flow meter to Tooling (H).
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    Illustration 23	g02682358
    (6) Main Supply Pressure (7) Transmission Lubrication Pressure

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

23. Connect a pressure gauge to pressure tap (6).

24. Connect pressure gauge (7) to Tooling (K).
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    Illustration 24	g02682516
    (8) No. 1 Proportional Valve (9) No. 2 Proportional Valve (10) No. 3 Proportional Valve (11) Forward Proportional Valve (12) Reverse Proportional Valve

25. Connect a pressure gauge to taps (8), (9), (10), (11), and (12), as shown.
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    Illustration 25	g02682556

26. Connect Tooling (L) to the transmission.
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    Illustration 26	g02682576

27. Connect Tooling (L) to a suitable location, as shown.
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    Illustration 27	g02685136

28. Cover the transmission. Use a suitable clean cover.
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    Illustration 28	g02629190
    Tooling (L)

29. Connect Tooling (L) to a power source. Refer to Tool Operating Manual, NEHS0996 for the correct operating instructions.

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

Test Procedure

TA3 Navigation

1. Select “Dozers”.

2. Select “D6N - 24V”.

Harness Test

1. Make sure that the harness is properly connected.

2. Use Tooling (L) to perform the harness test.

3. Record the values in Table 6.

   Note: Do not continue testing until harness test passes.

Start Checks

Note: Refer to Systems Operation, Testing and Adjusting, UENR0054, "D6N Track-Type Tractor Power Train" for the correct adjusting procedures.

1. If you are using SAE 10W oil, warm the oil to 50 °C (125.0 °F). If you are using Mobil DTE11 oil, warm the oil to 34 °C (95.0 °F). Maintain this temperature for the duration of the test.

2. Adjust the input flow to 38 ± 4 L/min (10 ± 1 US gpm).

3. Check the supply pressure. The correct supply pressure is 2723 ± 69 kPa (395 ± 10 psi).
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   Illustration 29	g02720621

4. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 500 ± 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.

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

6. Verify clutch engagement with Table 4.
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   Table 4

   Clutch Engagement
   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

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

8. The lubrication pressure must be between 48 kPa (7 psi) and 63 kPa (9 psi).

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

9. Record the value in Table 7.

Clutch Leakage Check

1. Adjust the Input Flow to 76 ± 4 L/min (20 ± 1 US gpm). Maintain this flow during this check.

2. Adjust the Input Rotation to 2200 ± 30 rpm in the NEUTRAL position.

3. Check the Supply Pressure. The correct Supply Pressure is 2826 ± 205 kPa (410 ± 30 psi).

4. Adjust the Input Rotation to 500 ± 30 rpm.

5. Shift the transmission to FORWARD 1.

6. Adjust the Input Rotation to 2200 ± 30 rpm.

7. Record the Input Flow in Table 8.

8. Record the Output Flow in Table 8.

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

10. Record the calculation in Table 8.

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

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

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

13. The difference in leakage between SECOND gear and THIRD gear or between FORWARD and REVERSEshould not exceed 2.3 L/min (0.60 US gpm).

14. The difference in leakage between FIRST gear and all other gears must not exceed 3.0 L/min (0.8 US gpm) of the average for this arrangement. Reference is 6.8 ± 3.0 L/min (1.80 ± 0.80 US gpm)

Lube Circuit Check

1. Adjust the input flow until the lube flow is 76 ± 4 L/min (20 ± 1 US gpm).

2. Adjust the input rotation to 500 ± 30 rpm.

3. Shift the transmission to FORWARD 2.

4. Adjust the input rotation to 2200 ± 30 rpm.

5. The lubrication pressure must be between 9 kPa (1.3 psi) of the average for this transmission arrangement. Reference is 207 ± 21 kPa (30 ± 3 psi).

6. Record the value in Table 9.

Speed Sensor Test

Note: Measure voltage across pins corresponding to pins 1 and 2 of the speed sensor. Output voltage must not be clipped with a diode. Filtered signals must have a corner frequency above 1 Khz.

1. Adjust the input flow to 38 ± 4 L/min (10 ± 1 US gpm).

2. Adjust the input rotation to 500 ± 5 rpm.

3. Shift the transmission to FORWARD 1.

4. Adjust the input rotation to 800 ± 5 rpm.
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   Illustration 30	g02682763
   Tooling (M)

5. Use Tooling (M) to measure the sensor signal voltage. Measure both speed sensors.

6. Record the values in Table 11.

7. Verify the test points with the values 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 12.

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

Transmission Bench Test Data Sheet

Solenoid Test

Start Checks

Clutch Leakage Check

Lube Circuit Check

Speed Sensor Test

ISO Particle Count