- 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
Revision     | Summary of Changes in REHS3607     | |
04     | Added new serial number prefixes.     |
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03     | Added serial number prefixes. Updated introduction.     |
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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
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- Caterpillar Technical Representative
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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 |
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. |
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. |
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.
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
- Install Tooling (A) to the input end of the transmission, as shown.
Note: Use the existing transmission bolts.
Illustration 2 | g02156396 |
- Use a hoist to install the transmission on the test bench. The weight of the transmission is 862 kg (1900 lb).
Illustration 3 | g02156401 |
- Install Tooling (B) on the input shaft.
Illustration 4 | g02156403 |
- Install Tooling (C) on Tooling (B) .
Illustration 5 | g02156407 |
- Install Tooling (D) on Tooling (C) .
Illustration 6 | g02156408 |
- Install Tooling (E) on Tooling (D) .
Illustration 7 | g02156410 |
- Align the transmission to the input drive shaft.
Illustration 8 | g02156413 |
- Connect the input drive shaft to Tooling (E) .
- Install the drive shaft guard.
Illustration 9 | g02156415 |
- Install Tooling (F) to the transmission to prevent movement during testing.
Illustration 10 | g02156417 |
Illustration 11 | g02723286 |
- Tighten all four jack bolts and castle nuts on test bench bed.
- Install Tooling (G) to the transmission case.
Illustration 12 | g02723297 |
- Install Tooling (H) onto Tooling (G)
Illustration 13 | g02723304 |
- Connect hose assembly (1) from the pressurized flow meter to Tooling (G) .
Note: The flow meter will measure the flow of the supply oil.
Illustration 14 | g02173034 |
Main Pump Supply |
- 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.
Illustration 15 | g02173053 |
Torque Converter (out) |
- Connect hose assembly (3) from the No. 2 flow meter (out) to Tooling (G) .
Illustration 16 | g03744216 |
Lube (in) |
- Connect pressure gauge (4) to Tooling (G) .
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.
- Connect pressure gauge (5) to Tooling (G) .
- Connect pressure gauge (6) to Tooling (G) .
- Remove cover plate (7) .
Illustration 18 | g02156431 |
- Install Tooling (J), as shown.
Illustration 19 | g02723314 |
- Remove cover (8) .
Illustration 20 | g02156435 |
- Install Tooling (K) .
Illustration 21 | g02156438 |
Direction Selector |
- Install Tooling (L) .
Illustration 22 | g02156439 |
Speed Selector |
- Install cover (8) .
- Connect pressure gauge (9) to Tooling (J) .
Illustration 23 | g02156465 |
(9) "P2" Speed Clutch Pressure (10) "P1" Direction Clutch Pressure |
- Connect pressure gauge (10) to Tooling (J) .
- Cover the transmission. Use a suitable clean cover.
Illustration 24 | g02723316 |
Test Procedure
Start Checks
- 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.
Note: Refer to Testing and Adjusting, KENR8564, "D6R Tractors Power Shift Transmission" for the correct adjusting procedures.
- Adjust the input flow to 55 ± 2 L/min (14.6 ± 0.5 US gpm).
- 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.
Illustration 25 | g02720621 |
- Shift the transmission through all directions and through all speed ranges in order to eliminate air from the transmission controls.
Illustration 26 | g01091561 |
- Stop the input rotation.
Initial Pressure Check
- 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.
Illustration 27 | g02723332 |
Top View |
- Adjust the input flow to 55 ± 2 L/min (14.6 ± 0.5 US gpm).
- With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 800 ± 30 rpm.
- The "P1" pressure must be 531 ± 34 kPa (77 ± 5 psi).
- Record the value in Table 6.
- The pressure for the priority valve must be 2551 ± 138 kPa (370 ± 20 psi). This pressure is measured at pressure tap (4) .
- Record the value in Table 6.
- Stop the input rotation.
- Stop the input flow.
- Install the load piston plug.
Torque Converter Inlet Ratio Valve Check
- Adjust the input flow to 55 ± 2L/min (14.6 ± 0.5 US gpm). Maintain this flow during this check.
- With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 800 ± 30 rpm.
- Shift the transmission to FORWARD 1.
- Use Tooling (H) to momentarily block the supply for the torque converter.
- The "P3" pressure must be 951 ± 55 kPa (138 ± 8 psi). This pressure is measured at pressure tap (5) .
- Open Tooling (H) .
- Record the value in Table 7.
Valve Check (Pressure Differential)
- Shift the transmission to the FORWARD 3.
- Adjust the input flow to 55 ± 2 L/min (14.6 ± 0.5 US gpm).
- Adjust the input rotation to 800 ± 30 rpm. The "P2" pressure must be 0 kPa (0 psi).
- Increase the input flow to 131 ± 1 L/min (34.7 ± 0.25 US gpm) .
- Increase the input rotation to 2110 ± 30 rpm. The "P2" pressure must remain at 0 kPa (0 psi).
- Adjust the input rotation to 800 ± 30 rpm.
- Shift the transmission to NEUTRAL and then shift the transmission to FORWARD 3.
- Adjust the input rotation to 2110 ± 30 rpm. The "P2" pressure must rise to normal pressure.
- Record the value in Table 8.
- Adjust the input rotation to 800 ± 30 rpm.
- Shift the transmission to NEUTRAL.
Lube Circuit Check
- Adjust the input flow until the lube flow is 76 ± 0.8 L/min (20.0 ± 0.2 US gpm).
- Adjust the input rotation to 800 ± 30 rpm.
- Shift the transmission to FORWARD 2.
- 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).
- Record the value in Table 9.
Clutch Leakage Check
- Adjust the input flow to 131 ± 1 L/min (34.7 ± 0.25 US gpm). Maintain this flow during this check.
- Adjust the input rotation to 800 ± 30 rpm in the NEUTRAL position.
- Shift the transmission to FORWARD 1.
- Adjust the input rotation to 2110 ± 30 rpm in the FORWARD 1 position.
- Record the input flow in Table 10.
- Record the output flow in Table 10.
- The leakage is obtained by subtracting the output flow from the input flow.
- Record the calculation in Table 10.
- Adjust the input rotation to 800 ± 30 rpm.
- 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.
- 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).
- 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
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
- Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.
- Record the results in Table 11.
- Remove the transmission from the test bench if the test bench oil supply is within specifications.
Transmission Bench Test Data Sheet
CATERPILLAR     | Transmission Bench Test Data Sheet     | Test Date:     |
Model: | ||
Work Order:     | Serial No.:     |
Initial Pressure Check
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
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)
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
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
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
Contamination Control     | Sample the test bench oil supply.     | ________/________Particle Count     |
______________________________________ Technician     |
______________________________________ Supervisor     |