Bench Test Procedure for a D9 and D9R Track-Type Tractor Transmission {3030, 3073} Caterpillar

Track-Type Tractor

D9 (S/N: JC21-UP; AK41-UP; J3D1-UP)

D9R (S/N: JJB1-UP; HWH1-UP; ACL1-UP; 8BL1-UP; WDM1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS1631
04	Added serial numbers AK4, J3D, and JC2. Added sales model D9.
03	Added serial number WDM. Standardized.
02	Added HWH serial number prefix.

© 2020 AVSpare 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 AVSpare: 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 AVSpare. 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 AVSpare.

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.

Table 2

Machine Model	Transmission Arrangement
D9R	6I-9231, 163-5299
D9	163-5299

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 AVSpare products. These warnings should be observed before performing any procedures. AVSpare 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.

AVSpare 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. AVSpare 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

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 to develop this test procedure.

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9585	Mounting Block Gp (Transmission)	1
	1U-9584	Rail As	2
	FT-2277	Support	2
	FT-2278	Swivel Head Support Gp	2
	9X-8883	Bolt (5/8-11X2.75 inch)	2
	4K-0367	Full Nut	2
B	FT-2276	Support	1
	0S-1569	Bolt (5/8-11X4.00 inch)	2
	5P-8247	Hard Washer	2
C	8P-8843	Yoke As	1
D	4C-4627	Adapter	1
	0S-1579	Bolt (1/2-20X2.00 inch)	4
	3B-4508	Lockwasher	4
E	136-3647	Drive Adapter As	1
	2J-5245	Bolt (3/8-16X1.25 inch)	4
	3B-4506	Lockwasher	4
F	1U-9131	Drive Adapter (Key)(1)	1
G	1U-9359	Drive Adapter(2)	1
H	1U-9722	Load Binder As (Ratchet Type)	3
	439-3940	Link Bracket As	3
	9X-8874	Bolt (1/2-13X3.00 inch)	2
	5P-8245	Hard Washer	2
	1F-7958	Full Nut	2
R	1U-9885	Adapter Plate	1
	9M-9647	O-Ring Seal	3
	8C-9024	Fitting As (Plain)	3
	9X-8879	Bolt (1/2-13X5.50 inch)	3
	5P-8245	Hard Washer	6
	1F-7958	Full Nut	3
J	8C-9024	Fitting As (Plain)	1
	8C-9025	Quick Coupler	1
	3B-7749	Fitting	1
	120-6843	Ball Valve	1
K	6V-3965	Fitting As (Quick Disconnect)	4
	3J-1907	O-Ring Seal	4
L	2M-2829	Control Rod	1
	0L-1170	Lever Handle	1
	0S-1588	Bolt (3/8-16X1.25 inch)	1
	9S-8752	Full Nut	1
M	4M-7307	Control Rod	1
	0L-1170	Lever Handle	1
	0S-1588	Bolt (3/8-16X1.25 inch)	1
	9S-8752	Full Nut	1
N	146-2728	Flexible Pickup Tool As	1
S	146-4080	Digital Multimeter	1
	5P-5677	Electrical Wire	1
	155-2270	Connecting Plug Kit	1
	186-3736	Connector Socket	2
		Plug As (Double Banana)(3)	1
P	8T-0862	Pressure Gauge (-100 to 500 kPa (-15 to 72 psi))	1
	6V-4144	Coupler	1
Q	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	4
	6V-4144	Coupler	4

(1)	This drive adapter is used with the small drive shaft.
(2)	This drive adapter is used with the large drive shaft.
(3)	Pomona Model 1330-0

FT Drawings

Illustration 3	g03831077
FT-2277

Illustration 4	g03836221
FT-2278 (A) 0L-1169 Bolt (B) 2S-7593 Hard Washer (C) 1D-4720 Nut

Illustration 5	g03857942
FT-2276

Installation Procedure

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Illustration 6	g03864005

1. Install Tooling (A) on the test bench, as shown.
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   Illustration 7	g00991379

2. Install Tooling (B) to the input end of the transmission, as shown.
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   Illustration 8	g00991380

3. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1360 kg (3000 lb).
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   Illustration 9	g00991381

4. Install Tooling (C) on the input shaft.
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   Illustration 10	g00991382

5. Install Tooling (D) on Tooling (C).
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   Illustration 11	g00991383

6. Install Tooling (E) on Tooling (D).
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   Illustration 12	g00991384

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

   Note: Tooling (F) will adapt to the small drive shaft. If you are using the large drive shaft, install Tooling (G) on Tooling (E).

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   Illustration 13	g00991389

8. Align the transmission to the input drive shaft.

9. Connect the input drive shaft to Tooling (F).
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   Illustration 14	g00991391

10. Install the drive shaft guard.
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    Illustration 15	g03802221

11. Tighten all four castle nuts and jack bolts.
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    Illustration 16	g00991392

12. Remove plug (1).
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    Illustration 17	g00991393

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    Illustration 18	g00991396

13. Install Tooling (H) to the rear of the transmission to prevent movement during testing.
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    Illustration 19	g00991397

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    Illustration 20	g00991398

14. Install Tooling (H) to the input end of the transmission.

    Note: Tooling (H) will locate the chain. Refer to Illustration 19.

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    Illustration 21	g03864014

15. Install Tooling (R).
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    Illustration 22	g03864028

16. Connect Tooling (J) to Tooling (R).
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    Illustration 23	g00991402
    (2) Supply oil

17. Connect hose assembly (2) from the pressurized flow meter to Tooling (R).
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    Illustration 24	g00991403
    (3) Torque Converter (out)

18. Connect hose assembly (3) 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 25	g00991404
    (4) Lube (in)

19. Connect hose assembly (4) from the No. 2 flow meter to Tooling (R).
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    Illustration 26	g00991405

20. Install Tooling (K) to four locations, as shown.
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    Illustration 27	g00991408

21. Remove cover (5).
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    Illustration 28	g00991409
    Direction Selector

22. Install Tooling (L).
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    Illustration 29	g00991411
    Speed Selector

23. Install Tooling (M).

24. Install cover (5).
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    Illustration 30	g00991412
    (6) Transmission main relief valve (main supply pressure) (7) Torque converter inlet oil pressure "P3" (8) Transmission lube pressure

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

25. Connect three pressure gauges to pressure taps (6), (7), and (8).
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    Illustration 31	g00991413
    (9) Direction Clutch Pressure "P2" (10) Speed Clutch Pressure "P1"

26. Connect two pressure gauges to pressure taps (9) and (10).
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    Illustration 32	g00991414

27. Cover The transmission. Use a clean suitable cover.

Test Procedure

Start Checks

Note: Refer to Testing and Adjusting , RENR3945 , "D9R 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 during the test.

2. Adjust the input flow to 57 ± 4 L/min (15 ± 1 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 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.

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   Illustration 34	g00992598

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

5. Stop the input shaft.

Initial Pressure Check

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Illustration 35	g00992242

1. Loosen the load piston plug on the top of the transmission control valve. DO NOT remove the load piston plug.
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   Illustration 36	g00992257

2. Use Tooling (N) to remove the load piston plug.

3. Adjust the input flow to 57 ± 4 L/min (15 ± 1 US gpm).

4. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 30 rpm.

5. The "P1" pressure must be 545 ± 35 kPa (79 ± 5 psi).

6. Record the value in Table 6.

7. The pressure for the priority valve must be 2206 ± 138 kPa (320 ± 20 psi). This pressure is measured at pressure tap (6).

8. Record the value in Table 6.

9. Stop the input rotation.

10. Stop the input flow.

11. Install the load piston plug.

Torque Converter Inlet Ratio Valve Check

1. Adjust the input flow to 57 ± 4 L/min (15 ± 1 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 700 ± 30 rpm.

3. Shift the transmission to FORWARD 1.

4. Use Tooling (J) to momentarily block the supply for the torque converter.

5. The converter inlet pressure must be 965 ± 55 kPa (140 ± 8 psi).

6. Open Tooling (J).

7. Record the value in Table 7.

Pressure Differential Valve Check

1. Shift the transmission to FORWARD 3.

2. Adjust the input flow to 57 ± 4 L/min (15 ± 1 US gpm).

3. Adjust the input rotation to 700 ± 30 rpm. The "P2" pressure must be 0 kPa (0 psi).

4. Adjust the input flow to 159 ± 4 L/min (42 ± 1 US gpm).

5. Adjust the input rotation to 1900 ± 30 rpm. The "P2" pressure must be 0 kPa (0 psi).

6. Adjust the input rotation to 700 ± 30 rpm.

7. Shift the transmission to NEUTRAL and then shift the transmission to any speed range.

8. Adjust the input rotation to 1900 ± 30 rpm. The "P2" pressure must rise to normal pressure. The normal pressure is determined by subtracting 379 ± 55 kPa (55 ± 8 psi) from the "P1" pressure.

9. Record the value in Table 8.

10. Adjust the input rotation to 700 ± 30 rpm.

11. Shift the transmission to NEUTRAL.

Lube Circuit Check

1. Adjust the input flow until the lube flow is 121 ± 4 L/min (32 ± 1 US gpm).

2. Shift the transmission to FORWARD 2.

3. Adjust the input rotation to 1900 ± 30 rpm.

4. The lube pressure must be within 9 kPa (1.3 psi) of the average for this transmission arrangement. Reference is 117 ± 14 kPa (17 ± 2 psi).

5. Record the value in Table 9.

Clutch Leakage Check

1. Adjust the input flow to 159 ± 4 L/min (42 ± 1 US gpm). Maintain this flow during this check.

2. Adjust the input rotation to 700 ± 30 rpm in the NEUTRAL position.

3. Shift the transmission to FORWARD 1.

4. Adjust the input rotation to 1900 ± 30 rpm in the NEUTRAL 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 700 ± 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.

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

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 6.5 ± 3.0 L/min (1.7 ± 0.8 US gpm) of the average for this arrangement.

Speed Sensor Test

Note: There is a speed sensor on 163-5299 Transmission Ar that must be tested.

1. Adjust the input flow to 57 ± 4 L/min (15 ± 1 US gpm).

2. Adjust the input rotation to 700 ± 5 rpm.

3. Shift the transmission to FORWARD 1.
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   Illustration 37	g03864041

4. Use Tooling (S) to measure the sensor signal voltage.

5. Record the value in Table 11.

6. The minimum voltage should be between 1.414 VRMS and 6.363 VRMS.

7. Record the values in Table 11.

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

Table 4

AVSpare	Transmission Bench Test Data Sheet
Work Order:________________________________	Test Date:_____________________________________
Model:_____________________________________	Serial No:_____________________________________
CURRENT MEDIA: REHS1631-04	MEDIA USED:__________________________________

Specifications

Table 5

General Specifications
Description	High Idle	Low Idle
Input Speed	1900 ± 30 rpm	700 ± 30 rpm
Input Flow	159 ± 4 L/min (42 ± 1 US gpm)	57 ± 4 L/min (15 ± 1 US gpm)
Minimum Lube Flow		39 L/min (10 US gpm)
Pressures
"P1" Initial(1)		545 ± 35 kPa (79 ± 5 psi)
Priority Valve(1)		2206 ± 138 kPa (320 ± 20 psi)
P1	2620 ± 138 kPa (380 ± 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)		965 ± 55 kPa (140 ± 8 psi)
Lube Reference	158 ± 21 kPa (23 ± 3 psi)	10 kPa (1.5 psi) Minimum

(1)	The load piston plug is removed and the transmission is in the NEUTRAL position.
(2)	The flow for the converter outlet is restricted.

Initial Pressure Check

Table 6

Initial Pressure

Input Speed (700 ± 30 rpm) Input Flow 57 ± 4 L/min (15 ± 1 US gpm)

_______kPa _______(psi)

Torque Converter Inlet Ratio Valve Check

Table 7

Torque Converter Inlet Ratio Valve Pressure

Input Speed (700 ± 30 rpm) Input Flow 57 ± 4 L/min (15 ± 1 US gpm)

_______kPa _______(psi)

Pressure Differential Valve Check

Table 8

Pressure Differential Valve Check
Input Flow	Input Speed	Gear Range	"P2" Pressure
57 ± 4 L/min (15 ± 1 US gpm)	700 ± 30 rpm	FORWARD 3	_______kPa _______(psi)
159 ± 4 L/min (42 ± 1 US gpm)	1900 ± 30 rpm	FORWARD 3	_______kPa _______(psi)
		NEUTRAL then shift to any gear range.	_______kPa _______(psi)

Lube Circuit Check

Table 9

Lube Circuit Check		Gear Range FORWARD 2 Input Speed (1900 ± 30 rpm) Lube Flow 121 ± 4 L/min (32 ± 1 US gpm)
Average Lube Pressure Of Arrangement	_______kPa _______(psi)	Lube Pressure	_______kPa _______(psi)

Clutch Leakage Check

Table 10

Clutch Leakage Check		Input Speed (1900 ± 30 rpm) Input Flow 159 ± 4 L/min (42 ± 1 US gpm)
Gear Range	1F	2F	3F	1R	2R	3R	N
Input Flow	______	______	______	______	______	______	______
Output Flow	______	______	______	______	______	______	______
Leakage	______	______	______	______	______	______	______
Average of Arrangement	______	______	______	______	______	______	______

Speed Sensor Test

Table 11

Speed Sensor Test	Input Speed (700 ± 5 rpm) Gear Range FORWARD 1
Output Speed Sensor	__________________ Volts/VRMS

Contamination Control

Table 12

ISO Particle Count

Sample the test bench oil supply.

________/________Particle Count

Table 13

______________________________________ Technician

______________________________________ Supervisor