Bench Test Procedure for a 589 Pipelayer and D8L Track-Type Tractor Transmission {3030, 3073} Caterpillar

Pipelayer

589 (S/N: 31Z1-UP)

Track-Type Tractor

D8L (S/N: 7YB1-UP; 7JC1-UP; 53Y1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS3279
02	Standardized.
01	Added new Introduction and Canceled Part Numbers section

© 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 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 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. To address an urgent need, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

• Cat Dealer Techinical Communicator

• Dealer Solution Network

• Cat Technical Representative

• Knowledge Network

Table 2

Machine Model	Transmission Arrangement
D8L	9P-6237
589	9P-6237

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.

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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

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
Tooling	Tool Number	Part Description	Qty
A	FT-0669	Drive Adapter	1
B	439-3939	Link Bracket As	2
C	1U-9584	Rail As	2
	FT-1586	Brackets	1
D	FT-1580	Adapter Plate	1
E	439-3939	Link Bracket As	2
	1U-9722	Load Binder As	2
F	8S-9967	Adapter	1
	8C-9024	Nipple (Quick Disconnect)	1
	6V-4144	Coupling	1
G	8S-9967	Adapter	1
	8C-9024	Nipple (Quick Disconnect)	1
	6V-4144	Coupling	1
	8S-9972	Coupler (Quick Disconnect)	1
	7X-7646	Nipple (Quick Disconnect)	1
	6B-9081	Bushing	1
	7F-6654	Nipple (Pipe)	1
	120-6843	Gate Valve	1
H	8S-9967	Adapter	1
	8C-9024	Nipple (Quick Disconnect)	1
	6V-4144	Coupling	1
J	7S-8887	Nipple (Quick Disconnect)	1
	5P-3501	Adapter	1
	3J-1907	O-Ring Seal	1
K	7S-8887	Nipple (Quick Disconnect)	1
	5P-3501	Adapter	1
	3J-1907	O-Ring Seal	1

FT Drawings

Illustration 3	g03871891
FT-0669 (A) 168.275 mm (6.625 inch) (B) 84.12 mm (3.312 inch) (C) 94.28 mm (3.712 inch) (D) 94.28 mm (3.712 inch) (E) Ø 6.4 ± 0.02 mm (0.252 ± 0.0008 inch) (F) 174.625 mm (6.875 inch) (G) 87.325 mm (3.438 inch) (H) 117.475 mm (4.625 inch) (J) 58.725 mm (2.312 inch) (K) Ø 13.45 mm (0.531 inch) 4 holes (L) 24.6 mm (0.969 inch) (M) 49.23 mm (1.938 inch) (N) 177.8 mm (7.0 inch) (P) 148.37 ± 0.01 mm (5.8415 ± 0.0005 inch) (Q) 114.3 mm (4.5 inch) (R) 70.37 ± 0.01 mm (2.7705 ± 0.0005 inch) (S) 42.875 mm (1.688 inch) (T) Ø 92.075 mm (3.625 inch) (U) Ø 10.31 mm (0.406 inch) (V) 90.07 ± 0.01 mm (3.546 ± 0.0005 inch) (W) Ø 8.2 mm (0.323 inch) (X) Ø 13.45 mm (0.531 inch) (Y) 209.51 ± 0.01 mm (8.2485 ± 0.0005 inch) (Z) 206.31 ± 0.01 mm (8.1225 ± 0.0005 inch)

Illustration 4	g03872166
FT-1586

Illustration 5	g03872175
FT-1580

Installation Procedure

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Illustration 6	g01311578

1. Install Tooling (A).
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   Illustration 7	g01311529

2. Install Tooling (B).
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   Illustration 8	g01311510

3. Install Tooling (C).
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   Illustration 9	g01311489

4. Install Tooling (D).
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   Illustration 10	g01311463

5. Install Tooling (E).

6. Use the hoist to install the transmission on the test bench. The weight of the transmission is 1353 kg (2983 lb).
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   Illustration 11	g01311323
   Typical example

7. Align the transmission with the input drive shaft.

8. Connect the input drive shaft to Tooling (A).
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   Illustration 12	g01311320
   Typical example

9. Install the drive shaft guard.
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   Illustration 13	g03802221

10. Tighten all four castle nuts and jack bolts.

11. Install Tooling (E) on input and output ends of transmission to prevent movement during testing.
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    Illustration 14	g01311310

12. Remove cover (1) to allow oil to drain into the oil sump of the test bench during testing.
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    Illustration 15	g01311296

13. Install Tooling (F).
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    Illustration 16	g01311291

14. Connect hose (2) from the test bench to Tooling (F).
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    Illustration 17	g01311269

15. Install Tooling (G).
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    Illustration 18	g01311285

16. Connect hose (3) from Tooling (G) to the No. 2 flow meter inlet.
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    Illustration 19	g01311256

17. Install Tooling (H).
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    Illustration 20	g01311246
    (4) Lube Flow

18. Connect hose (4) from the No. 2 flow meter outlet to Tooling (H).
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    Illustration 21	g01311242

19. Install Tooling (J).
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    Illustration 22	g01311225
    Speed Clutch Pressure and Initial Pressure "P1" (5)

20. Connect pressure tap (5) to Tooling (J).
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    Illustration 23	g01311208

21. Install Tooling (K).
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    Illustration 24	g01311196
    Directional Clutch Pressure "P2" (6)

22. Connect pressure tap (6) to Tooling (K).
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    Illustration 25	g01311124
    (7) Supply Pressure and Priority Valve Pressure (8) Torque Converter Inlet Pressure "P3" (9) Lubrication Pressure

23. Connect pressure tap (7), pressure tap (8), and pressure tap (9) to Tooling (D).

Test Procedure

Start Checks

Note: Refer to Testing and Adjusting, SENR2495, "589 Pipelayer Power Train" or Testing and Adjusting, SENR2336, "D8L 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 for the duration of the test.

2. Adjust the input flow to 68 ± 4 L/min (18 ± 1 US gpm).
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   Illustration 26	g02720621

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 10 rpm.

   Note: The input shaft will be rotated in a counterclockwise direction for the duration of the test. The direction is determined as you face the drive motor of the test bench.

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

5. Check for lockup or excessive drag in all gears.

6. Stop the input rotation.

7. Stop the input flow.

Initial Pressure Check

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Illustration 27	g01311644

1. Remove load piston plug (10) from the top of the transmission controls.

2. Adjust the input flow to 68 ± 4 L/min (18 ± 1 US gpm).

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

4. Shift the transmission into the NEUTRAL position.

5. Initial "P1" pressure must be 545 ± 34 kPa (79 ± 5 psi).

6. Stop the input rotation.

7. Stop the input flow.

8. Install load piston plug (10) into the top of the transmission controls.

9. Record the value in Table 6.

Priority Valve Pressure Check

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Illustration 28	g01311649

1. Remove load piston plug (10) from the top of the transmission controls.

2. Adjust the input flow to 68 ± 4 L/min (18 ± 1 US gpm).

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

4. Shift the transmission into the NEUTRAL position.

5. Priority valve pressure must be 2206 ± 34 kPa (320 ± 5 psi).

   Note: Add or remove spacers from the priority valve to adjust priority valve pressure. One spacer will adjust the pressure by 76 kPa (11 psi).

6. Stop the input rotation.

7. Stop the input flow.

8. Record the value in Table 7.

Pressure Differential Valve Check

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

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

3. Shift the transmission into FORWARD 3.

4. "P3" pressure should remain at 0 kPa (0 psi).

5. Shift the transmission into the NEUTRAL position.

6. Shift the transmission back into FORWARD 3.

7. "P1" pressure must be 2551 ± 69 kPa (370 ± 10 psi) and "P2" pressure must be P1 - 379 ± 55 kPa (55 ± 8 psi).

8. Shift the transmission into the NEUTRAL position.

9. Stop the input rotation.

10. Stop the input flow.

11. Record the values in Table 8.

Torque Converter Inlet Valve Pressure Check

1. Adjust the input flow to 68 ± 4 L/min (18 ± 1 US gpm).

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

3. Shift the transmission into any gear range except NEUTRAL.

4. Adjust Tooling (G) to temporarily block lube flow to the torque converter.

5. "P3" pressure must be 951 ± 55 kPa (138 ± 8 psi).

6. Adjust Tooling (G) to allow lube flow into the torque converter.

7. Shift the transmission into the NEUTRAL position.

8. Stop the input rotation.

9. Stop the input flow.

10. Record the value in Table 9.

Lube Pressure Check

1. Adjust the input flow to 121 L/min (32 US gpm).

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

3. Shift the transmission into FORWARD 2.

4. Lubrication pressure must be 68 ± 4 L/min (18 ± 1 US gpm).

5. Shift the transmission into the NEUTRAL position.

6. Stop the input rotation.

7. Stop the input flow.

8. Record the value in Table 10.

Lube Circuit Check

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

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

3. Shift the transmission into FORWARD 1.

4. Record the values of "P1", "P2", lubrication pressure, and lube flow in Table 11.

5. Shift the transmission through positions FORWARD 2, FORWARD 3, NEUTRAL, REVERSE 1, REVERSE 2, and REVERSE 3. Repeat Step 4 for each gear range.

   Note: Always shift the transmission back to NEUTRAL when shifting between forward and reverse.

6. Shift the transmission into the NEUTRAL position.

7. Stop the input rotation.

8. Stop the input flow.

9. Compare the recorded values with the specifications in Table 5.

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

CATERPILLAR	Transmission Bench Test Data Sheet	Test Date:_______
		Model:_______
Work Order:_______		Serial No.:_______

Specifications

Table 5

General Specifications
Description	Low Idle	High Idle
Input Speed	700 ± 10 rpm	1900 ± 10 rpm
Lube Flow	68 ± 4 L/min (18 ± 1 US gpm)	159 ± 4 L/min (42 ± 1 US gpm)
Pressures
"P1" Initial(1)	545 ± 34 kPa (79 ± 5 psi) minimum
Priority Valve(2)	2206 ± 34 kPa (320 ± 5 psi)
"P1"	2206 kPa (320 psi) minimum	2551 ± 69 kPa (370 ± 10 psi)
"P2"	P1 - 37 ± 55 kPa (55 ± 8 psi)	P1 - 379 ± 55 kPa (55 ± 8 psi)
"P3"	951 ± 55 kPa (138 ± 8 psi)
Lube Reference(3)		124 ± 7 kPa (18 ± 1 psi)

(1)	Initial "P1" pressure is measured while the load piston plug is removed and the transmission is in the NEUTRAL position.
(2)	Priority valve pressure is measured while the load piston plug is removed.
(3)	Lubrication pressure is measured while the input flow is adjusted to 121.13 L/min (32 US gpm) and the transmission is in FORWARD 2.

Initial Pressure Check

Table 6

Initial Pressure		Input Speed (700 ± 10 rpm)
		Input Flow 68 ± 4 L/min (18 ± 1 US gpm)
"P1"	_______kPa _______psi	"P2"	_______kPa _______psi

Priority Valve Pressure Check

Table 7

Priority Valve Pressure	Input Speed (700 ± 10 rpm)	_______kPa _______psi
	Input Flow 68 ± 4 L/min (18 ± 1 US gpm)

Pressure Differential Valve Check

Table 8

Pressure Differential Valve Pressure		Input Speed (1900 ± 10 rpm)
		Input Flow 159 ± 4 L/min (42 ± 1 US gpm)
"P1"	_______kPa _______psi	"P2"	_______kPa _______psi

Torque Converter Inlet Valve Pressure Check

Table 9

"P3" Torque Converter Inlet Valve Pressure	Input Speed (700 ± 10 rpm)	_______kPa _______psi
	Input Flow 68 ± 4 L/min (18 ± 1 US gpm)

Lube Pressure Check

Table 10

Lubrication Pressure	Input Speed (1900 ± 10 rpm)	_______kPa _______psi
	Input Flow 121 L/min (32 US gpm)

Lube Circuit Check

Table 11

Lube Circuit Check					Input Speed (1900 ± 10 rpm) Input Flow 159 ± 4 L/min (42 ± 1 US gpm)
Gear Range	N	F1	F2	F3	R1	R2	R3
"P1"	______	______	______	______	______	______	______
"P2"	______	______	______	______	______	______	______
Lubrication Pressure	______	______	______	______	______	______	______
Lube Flow	______	______	______	______	______	______	______
Average Lubrication Pressure of Arrangement					_______kPa _______psi

Contamination Control

Table 12

ISO Particle Count	Sample the test bench oil supply.	______/______ Particle Count
	ISO 4406 is 16/13.

Table 13

______________________________________ Technician

______________________________________ Supervisor