Bench Test Procedure For A D10T2 and D9T Track-Type Tractor Transmission {3030, 3073} Caterpillar

Track-Type Tractor

D10T2 (S/N: RAB1-UP; JJW1-UP)

D9T (S/N: REX1-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 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, 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 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

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 Table3 were used to develop this test procedure.

FT Drawings

Illustration 3	g01256261
Tooling (A)

Installation Procedure

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1. Install Tooling (A) on to the test stand.
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   Illustration 5	g03654686

2. Install Tooling (A) on test bench and transmission (two places).
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   Illustration 6	g03654697

3. Install Tooling (A) to the rear end of the transmission.

4. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1504 kg (3315 lb).
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5. Install Tooling (C) on Tooling (B).
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6. Install Tooling (D) on Tooling (C).
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   Illustration 9	g03659959

7. Install Tooling (E) on Tooling (D).
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   Illustration 10	g03654804

8. Install the tooling setup on the input end of the transmission.
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   Illustration 11	g03654805

9. Align the transmission to the input drive shaft.

10. Connect the input drive shaft to Tooling (E).
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    Illustration 12	g03654714

11. Close and latch drive shaft guard.
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    Illustration 13	g03780596

12. Tighten all four jack bolts and castle nuts on Tooling (A).
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    Illustration 14	g03654738

13. Remove cover plate (1).
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    Illustration 15	g03654721

14. Install Tooling (F) to the transmission to prevent movement during testing.
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    Illustration 16	g03654747

15. Install Tooling (G) on the transmission case.
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    Illustration 17	g03654754
    (2) Controls (in) (3) Controls (out) (4) Lube (in)

16. Connect hose assembly (2) from the pump supply to Tooling (G).

17. Connect hose assembly (3) from Tooling (G) to Flowmeter 1 (in).

18. Connect hose assembly (4) from Flowmeter 1 (out) to Tooling (G).
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    Illustration 18	g03654769
    (5) Pump pressure (6) Controls (out) (7) Lube pressure

19. Connect pressure gauges to pressure taps (5), (6), and (7).
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    Illustration 19	g03654784

20. Remove cover plate (8) and screen.
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    Illustration 20	g03648106
    (9) No. 3 clutch (10) No. 5 clutch (11) No. 4 clutch (12) No. 2 clutch (13) No. 1 clutch

21. Connect pressure gauges to pressure taps (9-13).
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    Illustration 21	g03654795

22. Connect Tooling (H) to the transmission.
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    Illustration 22	g03648168
    Tooling (J)

23. Connect Tooling (J) to a Tooling (H). 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 “D10T2-24V”, or “D9T-24V”.

Harness Test

1. Make sure that Tooling (H) is properly connected.

2. Use Tooling (J) to perform the solenoid test.

3. Document if Harness Test passed or failed in Table 6.

   Note: Do not continue testing until Harness Test passes.

Start Checks

Note: Refer to Testing and Adjusting, RENR7547, "D10T Track-Type Tractor Power Train".

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 61 ± 4 L/min (16 ± 1 US gpm).

3. Check the supply pressure. The correct supply pressure is 2896 ± 207 kPa (420 ± 30 psi).
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   Illustration 23	g02720621

4. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 20 rpm.

5. The lubrication pressure must be between 7 kPa (1 psi) and 29 kPa (4 psi) to continue.

   Note: If there is no lube pressure after 30 seconds, stop the test and verify test stand and transmission connections.

6. Shift the transmission through all gears to eliminate air from the transmission controls.

7. Confirm the correct clutch engagement with Table 4.
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   Table 4

   Clutch Engagement Check
   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

8. With the transmission in NEUTRAL position, measure Lube flow, Lube, Controls (out), and Main Relief Pressure.

9. Record the values in Table 9.

10. Confirm the values with Table 8.

    Note: If the values do not meet acceptable criteria, stop the test and verify test stand, instrumentation hook-ups, calibration, and/or repair/adjust the transmission.

11. With the transmission in NEUTRAL position, adjust the input flow to 159 ± 3.8 L/min (42 ± 1 US gpm).

12. Adjust the input rotation to 1900 ± 20.

13. Wait until flows and pressures stabilize.

14. Repeat Steps 8 through 10.

Clutch Leakage Check

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

2. Adjust the input rotation to 700 ± 20 rpm.

3. Shift the transmission to FORWARD 1.

4. Record the input flow and output flow in Table 11.

5. The leakage is obtained by subtracting the output flow from the input flow. Record the calculation in Table 11.

6. Shift the transmission to FORWARD 2.

7. Repeat Steps 4 and 5.

8. With the transmission in NEUTRAL, adjust the input rotation to 700 ± 20 rpm.

9. Shift the transmission to FORWARD 1.

10. Adjust the input rotation to 1900 ± 20 rpm.

11. Record the input flow and output flow in Table 10.

12. The leakage is obtained by subtracting the output flow from the input flow. Record the calculation in Table 11.

13. Adjust the input rotation to 700 ± 15 rpm.

14. Shift the transmission through positions FORWARD 2, FORWARD 3, REVERSE 1, REVERSE 2, REVERSE 3, and NEUTRAL. Repeat Steps 10 through 13 for each gear range.

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

15. Reference Table 10 for correct leakage specifications.

Lube Circuit Check

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

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

3. Shift the transmission to FORWARD 2.

4. Adjust the input rotation to 1900 ± 20 rpm.

5. The Lube pressure must be between 145 kPa (21 psi) and 179 kPa (26 psi).

6. Record the value in Table 12.

High Idle Pressure Check

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

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

3. Shift the transmission into FORWARD 1.

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

5. Record Clutch pressures in Table 14.

6. Confirm values with Table 13.

7. Repeat steps 2 through 5 for all gear ranges.

Electronic Main Relief Valve (eMRV) Check

Note: This check is to prove the function of the valve.

1. With the transmission in NEUTRAL position, adjust the input flow to 159 ± 4 L/min (42 ± 1 US gpm).

2. Adjust the input rotation to 1900 ± 20 rpm.

3. Select the tab marked “eMRV High Current/Low Pressure” on the test screen.

   Note: Do not exceed 10 seconds at this setting.

4. Record Main Relief pressure in Table 15. Confirm that the Main Relief pressure is 1344 ± 207 kPa (195 ± 30 psi) to verify the valves response.

5. Select the tab marked “eMRV Low Current/High Pressure” on the test screen.

6. Record Main Relief pressure in Table 15. Confirm that Main Relief pressure is 3309 ± 207 kPa (480 ± 30 psi) to verify the valves response.

Speed Sensor Test

Note: This transmission arrangement has two speed sensors that must be tested.

1. Adjust the input flow to 61 ± 4 L/min (16 ± 1 US gpm).

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

3. Shift the transmission to FORWARD 1.

4. Record the speed sensor values in Table 16.

5. The transmission output speed should be 219 ± 10 rpm.

Contamination Control

1. Take and oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.

2. Record the results in Table 17.

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

Transmission Bench Test Data Sheet

Harness Test

Start Checks

Clutch Leakage Check

Lube Circuit Check

High Idle Pressure Check

Electronic Main Relief Valve (eMRV) Check

Speed Sensor Test

Contamination Control