Bench Test Procedure for a D8R and D8N Track-Type Tractor Transmission {0599, 0717, 3030} Caterpillar

Track-Type Tractor

D8N (S/N: 5TJ1-UP; 7TK1-UP)

D8R (S/N: MEJ1-UP; RJM1-UP; 7XM1-UP; 9EM1-UP; T5X1-UP)

Introduction

© 2016 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 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 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.

Show/hide table

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.

Show/hide table

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Show/hide table

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.

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

Show/hide table

Illustration 6	g03856984

1. Install Tooling (A) on the test bench, as shown.
   Show/hide table

   Illustration 7	g00991379

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

   Illustration 8	g00991380

3. Use a hoist to install the transmission onto Tooling (A). The weight of the transmission is 1360 kg (3000 lb).
   Show/hide table

   Illustration 9	g00991381

4. Install Tooling (C) on the input shaft.
   Show/hide table

   Illustration 10	g00991382

5. Install Tooling (D) on Tooling (C).
   Show/hide table

   Illustration 11	g00991383

6. Install Tooling (E) on Tooling (D).
   Show/hide table

   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).

   Show/hide table

   Illustration 13	g00991389

8. Align the transmission to the input drive shaft.

9. Connect the input drive shaft to Tooling (F).
   Show/hide table

   Illustration 14	g00991391

10. Install the drive shaft guard.
    Show/hide table

    Illustration 15	g03802221

11. Tighten all four castle nuts and jack bolts.
    Show/hide table

    Illustration 16	g00991392

12. Remove the plug (1).
    Show/hide table

    Illustration 17	g00991393

    Show/hide table

    Illustration 18	g00991396

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

    Illustration 19	g00991397

    Show/hide table

    Illustration 20	g00991398

14. Install Tooling (H) to the input end of the transmission.
    Show/hide table

    Illustration 21	g03392816

15. Install Tooling (R).
    Show/hide table

    Illustration 22	g03392820

16. Connect Tooling (J) to Tooling (R).
    Show/hide table

    Illustration 23	g00991402
    (2) Supply Oil

17. Connect hose assembly (2) from the pressurized flow meter to Tooling (R).
    Show/hide table

    Illustration 24	g00991403
    (3) Torque converter (out)

18. Connect hose assembly (3) from Tooling (J) to No. 2 flow meter inlet.
    Show/hide table

    Illustration 25	g00991404
    (4) Lube (in)

19. Connect hose assembly (4) from the No. 2 flow meter to Tooling (R).
    Show/hide table

    Illustration 26	g00991405

20. Install Tooling (K), as shown.
    Show/hide table

    Illustration 27	g00991408

21. Remove cover (5).
    Show/hide table

    Illustration 28	g00991409
    Direction Selector

22. Install Tooling (L).
    Show/hide table

    Illustration 29	g00991411
    Speed Selector

23. Install Tooling (M).

24. Install cover (5).
    Show/hide table

    Illustration 30	g00991412
    (6) Main Supply Pressure (7) Torque converter inlet oil pressure "P3" (8) 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).
    Show/hide table

    Illustration 31	g00991413
    (9) Direction Clutch Pressure "P2" (10) Speed Clutch Pressure "P1"

26. Connect two pressure gauges to pressure taps (9) and (10).
    Show/hide table

    Illustration 32	g00991414

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

Test Procedure

Start Check

Note: Refer to Testing and Adjusting, SENR8326, "D8R 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 30 ± 4 L/min (8 ± 1 US gpm).
   Show/hide table

   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.

   Show/hide table

   Illustration 34	g00992598

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 3 seconds, stop input rotation and check connections on test bench and transmission.

5. Stop the input shaft.

Initial Pressure Check

Show/hide table

Illustration 35	g00992242

1. Loosen the load piston plug on the top of the transmission control valve. DO NOT remove the load piston plug.
   Show/hide table

   Illustration 36	g00992257

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

3. Adjust the input flow to 30 ± 4 L/min (8 ± 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 531 ± 34 kPa (77 ± 5 psi).

6. Record the value in Table 6.

7. The pressure for the priority valve must be 2482 ± 276 kPa (360 ± 40 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 30 ± 4 L/min (8 ± 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 30 ± 4 L/min (8 ± 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 87 ± 4 L/min (23 ± 1 US gpm).

5. Adjust the input rotation to 2100 ± 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 directional position.

8. Adjust the input rotation to 2100 ± 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 76 ± 8 L/min (20 ± 2 US gpm).

2. Shift the transmission to FORWARD 2.

3. Adjust the input rotation to 2100 ± 30 rpm.

4. The lube pressure must be within 21 kPa (3 psi) of the average for this transmission arrangement. Reference is 117 ± 17 kPa (17 ± 3 psi).

5. Record the value in Table 9.

Clutch Leakage Check

1. Adjust the input flow to 87 ± 4 L/min (23 ± 1 US gpm). Maintain this flow during this check.

2. Adjust the input rotation to 2100 ± 30 rpm in the NEUTRAL position.

3. Shift the transmission to FORWARD 1.

4. Adjust the input rotation to 2100 ± 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 3, REVERSE 2, REVERSE 1, 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 6.1 ± 3.0 L/min (1.6 ± 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 30 ± 4 L/min (8 ± 1 US gpm).

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

3. Shift the transmission to FORWARD 1.
   Show/hide table

   Illustration 37	g03392848

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

Specifications

Initial Pressure Check

Torque Converter Inlet Ratio Valve Check

Pressure Differential Valve Check

Lube Circuit Check

Clutch Leakage Check

Speed Sensor Test

Contamination Control