Bench Test Procedure for a D8R and D8TTrack-Type Tractor and a PL83 and PL87 Pipelayer Transmission {3030, 3073, 3139} Caterpillar

Pipelayer

PL83 (S/N: CB21-UP; KSD1-UP; DLW1-UP)

PL87 (S/N: TEC1-UP; ZAC1-UP)

Track-Type Tractor

D8R (S/N: JR81-UP; DWJ1-UP)

D8T (S/N: JJ51-UP; MB81-UP; J8B1-UP; FMC1-UP; MLN1-UP; FCT1-UP; JET1-UP; KPZ1-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 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

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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

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. These tools are suggested and may very depending on availability and bench configuration.

FT Drawings

Illustration 3	g03823820
FT-1665 (A) 44.45 mm (1.75 inch) (B) 12.7 mm (0.5 inch) (C) 31.75 mm (1.25 inch) (D) Ø 149.23 mm (5.875 inch) (E) Ø 140.45 mm (5.53 inch) (F) 94.28 mm (3.71 inch) (G) 47.14 mm (1.86 inch) (H) 94.28 mm (3.71 inch) (I) 47.14 mm (1.86 inch) (J) 42.88 mm (1.69 inch) (K) 21.44 mm (0.844 inch) (L) Ø 8.2 mm (0.3 inch), 25.4 mm (1.0 inch) Deep, 3/8-12-2B THD (M) Ø 10.5 mm (0.4 inch), Ø 22.2 mm (0.874 inch) Bore, 14 mm (0.55 inch) Deep (N) Ø 92.0 mm (3.622 inch) (O) 57.15 mm (2.25 inch) (P) 114.3 mm (4.5 inch)

Installation Procedure

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1. Install Tooling (A) on the test bench, as shown.
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   Illustration 5	g01465949

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   Illustration 6	g02336596

2. Install Tooling (B) in order to lift the transmission.
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   Illustration 7	g01457425

3. Remove Brackets (1).
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   Illustration 9	g02344516

4. Remove Cover Plate (2) and the Filter Screen (2).
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5. Install Tooling (A) to the input end of the transmission, as shown.

   Note: Use the transmission bolts that were removed in step 3.

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6. Use a hoist to install the transmission on the test bench. The weight of the transmission is 907 kg (2000 lb).
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7. Install Tooling (B) to the transmission to prevent movement of the transmission during installation.

   Note: Over-tightening Tooling (B) can jeopardize the tightening ability of the castle nuts on Tooling (A) later in this section.

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8. Install Tooling (C) on the Input Shaft.
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9. Install Tooling (D) on Tooling (C).
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10. Install Tooling (E) on Tooling (D).
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11. Install Tooling (F) on Tooling (E).
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    Illustration 17	g01457519

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

13. Connect the input drive shaft to Tooling (F).
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    Illustration 18	g01457528

14. Install the drive shaft guard.
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    Illustration 19	g03802221

15. Tighten all four castle nuts and jack bolts.

16. Tighten Tooling (B) to prevent movement of the transmission during testing.
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    Illustration 20	g02337738

17. Install Tooling (G) to the transmission case.

    Note: The center port is blocked internally.

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    Illustration 21	g02349860

18. Remove Plug (3).
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    Illustration 22	g02339557

19. Install Tooling (H).
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    Illustration 23	g02342888

20. Remove cover (4).
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    Illustration 24	g02342936

21. Remove main relief valve (5).
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    Illustration 25	g03411339

22. Install tooling (N) under main relief valve. Torque bolts to 24 N·m (18 lb ft).
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    Illustration 26	g03825998
    Controls (in)

23. Connect Hose Assembly (6) from the pressurized flow meter to Tooling (G).
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    Controls (out)

24. Connect Hose Assembly (7) from Tooling (N) to the inlet of the No. 2 flow meter.
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    Illustration 28	g02339656
    (8) Transmission Lubrication Supply

25. Connect Hose Assembly (8) from the outlet of the No. 2 flow meter to Tooling (H).
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    Illustration 29	g02342767
    (9) Supply Pressure 0 - 4000 kPa (0 - 580 psi) (10) Lubrication Oil Pressure 0 - 965 kPa (0 - 140 psi)

26. Install Pressure Gauge (9) and (10).
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    Illustration 30	g02342856
    0 - 4000 kPa (0 - 580 psi) (11) Pressure tap for the No. 5 clutch (12) Pressure tap for the No. 4 clutch (13) Pressure tap for the No. 3 clutch (14) Pressure tap for the No. 2 clutch (15) Pressure tap for the No. 1 clutch

27. Install Pressure Gauges (11), (12), (13), (14) and (15).
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    Illustration 31	g03411344

28. Connect Tooling (K) to the transmission.
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    Illustration 32	g02343996

29. Connect Ground Clamp (16) to a suitable area.
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    Illustration 33	g01457869
    Tooling (L)

30. Connect Tooling (K) to Tooling (L). Connect Tooling (L) to a power source. Refer to Tool Operating Manual, NEHS0966 for the correct operating instructions.
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    Illustration 34	g01457863

31. Cover the transmission. Use a suitable clean cover.

Test Procedure

TA3 Navigation

1. Select “Dozers”.

2. Select “D8T - 24V”.

Harness Test

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

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

3. Record the values in Table 6.

   Note: Do not continue test until Harness Test passes.

Start Checks

Note: Refer to Testing and Adjusting, KENR8927, "D8T Track-Type 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 57 ± 4 L/min (15 ± 1 US gpm).

3. Check the Supply Pressure. The correct Supply Pressure is 2800 ± 100 kPa (406 ± 15 psi).
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   Illustration 35	g02720621

4. 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.

5. The Lubrication Oil Pressure must be between 41 kPa (6 psi) and 62 kPa (9 psi).

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

6. Record the value in Table 7.

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

8. Shift the transmission until all clutch fills are consistent.

9. Verify correct clutch engagement with Table 4.
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   Table 4

   Clutch Engagement
   Gear	Clutch 1	Clutch 2	Clutch 3	Clutch 4	Clutch 5
   N			X
   F1		X			X
   F2		X		X
   F3		X	X
   R1	X				X
   R2	X			X
   R3	X		X

Lubrication Circuit

1. Adjust the Lubrication Oil Flow to 76 ± 4 L/min (20 ± 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 2100 ± 30 rpm.

5. The Lubrication Oil Pressure must be within 14 kPa (2 psi) of the average of this arrangement. The reference is 103 ± 14 kPa (15 ± 2 psi).

6. Record the value in Table 8.

Clutch Leakage Check

1. Adjust the Input Flow to 98 ± 3.8 L/min (26 ± 1 US gpm). Maintain this flow during this check.

2. Adjust the Input Rotation to 2100 ± 30 rpm in the NEUTRAL position.

3. Check the Supply Pressure. The correct Supply Pressure is 2980 ± 205 kPa (432 ± 30 psi).

4. Adjust the Input Rotation to 700 ± 30 rpm.

5. Shift the transmission to FORWARD 1.

6. Adjust the Input Rotation to 2100 ± 30 rpm.

7. Record the Input Flow in Table 9.

8. Record the Output Flow in Table 9.

9. The leakage is obtained by subtracting the Output Flow from the Input Flow.

10. Record the calculation in Table 9.

11. Adjust the Input Rotation to 700 ± 30 rpm.

12. Shift the transmission through positions FORWARD 2, FORWARD 3, REVERSE 1, REVERSE 2, REVERSE 3, and NEUTRAL. Repeat Steps 6 through 11 for each gear range.

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

13. The difference in leakage between SECOND gear and THIRD gear or between FORWARD and REVERSEshould not exceed 2.3 L/min (0.6 US gpm).

14. 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 5.4 ± 3.0 L/min (1.4 ± 0.8 US gpm)

Speed Sensor Test

Note: This transmission arrangement has two output speed sensors 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.
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   Illustration 36	g01457859

4. Use Tooling (P) to measure the sensor signal voltage. Measure each output speed sensor.

5. Record the values in Table 10.

6. The voltage must be between 1.1 VRMS and 4.6 VRMS.

7. Verify that both output speed sensors continue to have output.

8. Record the values in Table 10.

High Idle Pressure Check

1. Adjust the input flow to 98 ± 4 L/min (26 ± 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 2130 ± 30 rpm.

5. Record the clutch pressure in Table 12.

6. Verify clutch pressures with Table 11.

7. Repeat steps 1 through 5 for all gear ranges.

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 13.

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

Transmission Bench Test Data Sheet

Harness Test

Start Checks

Lubrication Circuit

Clutch Leakage Check

Speed Sensor Test

High Idle Pressure Check

ISO Particle Count