Bench Test Procedure for a D9R Track-Type Tractor Transmission with Differential Steering {3030, 3073} Caterpillar


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Bench Test Procedure for a D9R Track-Type Tractor Transmission with Differential Steering {3030, 3073} [REHS1632]
POWER TRAIN
CONTROL GP-TRANSMISSION HYD
Bench Test Procedure for a D9R Track-Type Tractor Transmission with Differential Steering {3030, 3073}
1.1. Introduction
2.1. Canceled Part Numbers and Replaced Part Numbers
3.1. Important Safety Information
4.1. Collecting the Test Data
5.1. Tools Needed
6.2. FT Drawings
7.1. Installation Procedure
8.1. Test Procedure
9.2. Start Checks
10.2. Initial Pressure Check
11.2. Torque Converter Inlet Ratio Valve Check
12.2. Pressure Differential Valve Check
13.2. Lube Circuit Check
14.2. Clutch Leakage Check
15.2. Speed Sensor Test
16.2. Specifications
17.2. Contamination Control
18.1. Transmission Bench Test Data Sheet
19.2. Initial Pressure Check
20.2. Torque Converter Inlet Ratio Valve Check
21.2. Pressure Differential Valve Check
22.2. Lube Circuit Check
23.2. Clutch Leakage Check
24.2. Speed Sensor Test
25.2. ISO Particle Count
Track-Type Tractor
D9R (S/N: ABK1-UP; 7TL1-UP)

Introduction

Table 1
Revision  Summary of Changes in REHS1632 
07  Updated Tooling C in Table 3. 
06  Update Initial Pressure Check, Step6 and Table 4. 
05  Updated "Initial Pressure Check" section.
Standardized. 
04  Updated Introduction.
Updated Priority Valve pressure in low idle. 
03  Updated Table 9. 

© 2017 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 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 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  6Y-9049, 163-5294 

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 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 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.

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 often used 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.

------ 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

Note: Pressures will be sensitive to tooling setup. The diameter of the hose, the diameter of a fitting, and extra filtering can affect pressure. The required tools that are listed in Table 3 were used to develop this test procedure. For additional information about tooling, consult AVSpare Service Technology Group (800) 542-8665.

Table 3
Required Tools 
Tool  Part Number  Part Description  Qty 
1U-9585  Mounting Block Gp (Transmission) 
1U-9584 Rail As 
FT-2277 Support 
FT-2278 Swivel Head Support Gp 
9X-8883 Bolt (5/8-11X2.75 inch) 
4K-0367 Full Nut 
(1)  Support As 
8E-9466  Yoke 
4C-4627  Adapter 
0S-1579 Bolt (1/2-20X2.00 inch) 
3B-4508 Lockwasher 
136-3647  Drive Adapter As 
2J-5245 Bolt (3/8-16X1.25 inch) 
3B-4506 Lockwasher 
1U-9131  Drive Adapter (Key)(2) 
1U-9359  Drive Adapter(3) 
1U-9722  Load Binder As (Ratchet Type) 
138-7575 Link Bracket 
9X-8874 Bolt (1/2-13X3.00 inch) 
5P-8245 Hard Washer 
1F-7958 Full Nut 
1U-9885  Adapter Plate 
9M-9647 O-Ring Seal 
8C-9024 Fitting As (Plain) 
9X-8879 Bolt (1/2-13X5.50 inch) 
5P-8245 Hard Washer 
1F-7958 Full Nut 
8C-9024  Fitting As (Plain) 
8C-9025 Quick Coupler 
3B-7749 Fitting 
120-6843 Ball Valve 
6V-3965  Fitting As (Quick Disconnect) 
3J-1907 O-Ring Seal 
2M-2829  Control Rod 
0L-1170 Lever Handle 
0S-1588 Bolt (3/8-16X1.25 inch) 
9S-8752 Full Nut 
4M-7307  Control Rod 
0L-1170 Lever Handle 
0S-1588 Bolt (3/8-16X1.25 inch) 
9S-8752 Full Nut 
146-4080  Digital Multimeter 
5P-5677 Electrical Wire 
155-2270 Connecting Plug Kit 
186-3736 Connector Socket 
Plug As (Double Banana)(4) 
8T-0862  Pressure Gauge (-100 to 500 kPa (-15 to 72 psi)) 
6V-4144 Coupler 
8T-0855  Pressure Gauge (0 to 4,000 kPa (0 to 580 psi)) 
6V-4144 Coupler 
(1) Refer to Illustration 3 for further information.
(2) This drive adapter is used with the small drive shaft.
(3) This drive adapter is used with the large drive shaft.
(4) Pomona Model 1330-0


Illustration 3g00995051

FT Drawings



Illustration 4g03831077
FT-2277


Illustration 5g03836221
FT-2278
(A) 0L-1169 Bolt (5/8-11 THD x 95.25)
(B) 2S-7593 Hard Washer
(C) 1D-4720 Nut

Installation Procedure



    Illustration 6g00991377

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


    Illustration 7g00995014

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


    Illustration 8g00995015

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


    Illustration 9g00995016

  4. Install Tooling (C) on the input shaft.


    Illustration 10g00995017

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


    Illustration 11g00995019

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


    Illustration 12g00995020

  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).



    Illustration 13g00995022

  8. Use hoist and pry bars to align the transmission to the input drive shaft.

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


    Illustration 14g00995024

  10. Install the drive shaft guard.


    Illustration 15g03802221

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


    Illustration 16g00991392

  12. Remove the plug (1).


    Illustration 17g00995025


    Illustration 18g00995026

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


    Illustration 19g00995027


    Illustration 20g00995028

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

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



    Illustration 21g03125577

  15. Install Tooling (Q).


    Illustration 22g03125579

  16. Connect Tooling (J) to Tooling (Q).


    Illustration 23g00995032
    (2) Main relief valve (main supply pressure)

  17. Connect hose assembly (2) from the pressurized flow meter to Tooling (Q).


    Illustration 24g00995033
    (3) Torque Converter (out)

  18. Connect hose assembly (3) from Tooling (J) to the No. 2 flow meter inlet.


    Illustration 25g00995035
    (4) Lube (in)

  19. Connect hose assembly (4) from the No. 2 flow meter to Tooling (Q).


    Illustration 26g00995037

  20. Install Tooling (K), as shown.


    Illustration 27g00995039

  21. Remove cover (5).


    Illustration 28g00995041
    Direction Selector

  22. Install Tooling (L).


    Illustration 29g00995042
    Speed Selector

  23. Install Tooling (M).

  24. Install cover (5).


    Illustration 30g00995044
    (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).


    Illustration 31g00995045
    (9) Direction Clutch Pressure "P2"
    (10) Speed Clutch Pressure "P1"

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


    Illustration 32g00995046

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

Test Procedure

Start Checks

    Note: Refer to Testing and Adjusting, RENR3945, "D9R Track-Type Tractor" 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 57 ± 4 L/min (15 ± 1 US gpm).


    Illustration 33g02720621

  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.



    Illustration 34g00995121

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

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

  5. Stop the input rotation.

Initial Pressure Check



    Illustration 35g00995162
    Top View

  1. Remove the load piston plug from the top of the transmission control valve.

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

  3. With the transmission in the NEUTRAL position, adjust the input rotation to 700 ± 30 rpm.

  4. The "P1" pressure must be 531 ± 35 kPa (77 ± 5 psi).

  5. Record the value in Table 6.

  6. The pressure for the priority valve must be 2896 ± 138 kPa (320 ± 20 psi). This pressure is measured at pressure tap (6).

  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 57 ± 4 L/min (15 ± 1 US gpm). Maintain this flow during this check.

  2. With the transmission in the NEUTRAL position, 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 952 ± 83 kPa (138 ± 12 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 160 ± 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 lube flow 76 ± 4 L/min (20 ± 1 US gpm).

  2. Shift the transmission to FORWARD 3.

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

  4. The lube pressure must be within 21 kPa (3 psi) of the average for this transmission arrangement. Reference is 162.0 ± 21 kPa (23.5 ± 3 psi).

  5. Record the value in Table 9.

Clutch Leakage Check

  1. Adjust the input flow to 160 ± 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 the transmission 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 3.0 L/min (0.8 US gpm) of the average for this arrangement. Reference is 6.5 ± 3.0 L/min (1.7 ± 0.8 US gpm).

Speed Sensor Test

    Note: There is a speed sensor on 163-5294 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.


    Illustration 36g00995179

  4. Use Tooling (N) 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.

Specifications

Table 4
General Specifications 
Description  High Idle  Low Idle 
Input Speed  1900 ± 30 rpm  700 ± 30 rpm 
Input Flow  160 ± 4 L/min (42 ± 1 US gpm)  57 ± 4 L/min (15 ± 1 US gpm) 
Minimum Lube Flow  140.0 L/min (37.0 US gpm)  34.0 L/min (9.0 US gpm) 
Pressures 
"P1" Initial(1)    531 ± 35 kPa (77 ± 5 psi) 
Priority Valve(1)    2896 ± 138 kPa (320 ± 20 psi) 
P1  2620 ± 138 kPa (380 ± 20 psi)  2206 ± 138 kPa (320 ± 20 psi) min 
P2  P1 − 379 ± 55 kPa (P1 − 55 ± 8 psi)  P1 − 379 ± 55 kPa (P1 − 55 ± 8 psi) 
P3(2)    952 ± 83 kPa (138 ± 12 psi) 
Lube Reference  117 ± 21 kPa (17 ± 3 psi)  24 kPa (3.5 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.

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

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) 
160 ± 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 3
Input Speed (700 ± 30 rpm)
Lube Flow 76 ± 4 L/min (20 ± 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 160 ± 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 

ISO Particle Count

Table 12
ISO Particle Count  Sample the test bench oil supply.  ________/________Particle Count 

Table 13






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