- Pipelayer:
- PL87 (S/N: KKJ1-UP)
Introduction
Revision     | Summary of Changes in REHS3627     |
01     | Standardized.     |
© 2015 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 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 need, use the following resources to communicate your request to Caterpillar Repair Process Engineering:
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Machine Model     | Transmission Arrangement     |
PL87     | 362-9154     |
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 in order 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 in order 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.
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. |
Tools Needed
Required Tools     | |||
---|---|---|---|
Tool     | Part Number     | Part Description     | Qty     |
A     | 1U-9584     | Rail As     | 2     |
1U-9585 | Mounting Block Gp     | 1     | |
1U-9586 | Swivel Head Support Gp     | 1     | |
B     | 439-3940     | Link Bracket As     | 3     |
0L-1329 | Bolt (1/2-13X3 inch)     | 2     | |
4B-5273 | Washer     | 2     | |
1D-4719 | Full Nut     | 2     | |
1U-9722 | Ratcheting Turnbuckle     | 3     | |
C (1)     | 3T-8305     | Yoke As     | 1     |
9G-1930 | Yoke As     | 1     | |
D     | FT-1665     | Drive Adapter     | 1     |
0L-0478 | Bolt (3/8-24X1.75 inch)     | 4     | |
3B-4506 | Lockwasher     | 4     | |
E     | 136-3647     | Drive Adapter As     | 1     |
0S-1594 | Bolt (3/8-16X1 inch)     | 4     | |
3B-4506 | Lockwasher     | 4     | |
F     | 1U-9131     | Drive Adapter (Key)     | 1     |
G     | 1U-7044     | Lube Adapter     | 1     |
4J-0520 | O-Ring Seal     | 3     | |
8C-9024 | Nipple Assembly (Plain)     | 1     | |
6V-3966 | Nipple Assembly (Valve)     | 3     | |
Plug | Plug (1-11 1/2 NPTF inch)     | 1     | |
7X-0341 | Bolt (1/2-13X7 inch)     | 2     | |
8T-4223 | Hard Washer     | 4     | |
6V-8188 | Nut     | 2     | |
H     | 8C-9024     | Nipple Assembly (Plain)     | 1     |
3T-9549 | Adapter     | 1     | |
5P-0492 | Adapter     | 1     | |
J     | 175-2599     | Plug (Expandable)     | 1     |
K     | 4C-6818     | Pressure Sensor (500 psi)     | 6     |
L     | 4C-6816     | Pressure Sensor (60 psi)     | 1     |
M     | 256-7623     | Test Cable As     | 1     |
306-0397 | Extension Cable     | 1     | |
300-4993 | Adapter Cable As     | 1     | |
N     | 9U-7500     | Transmission Analyzer Tool Gp     | 1     |
OR | |||
277-2362 | Transmission Analyzer III Gp     | 1     | |
P     | 146-4080     | Digital Multimeter     | 1     |
R     | FT-3205     | Relief Valve Assembly     | 1     |
( 1 ) | The Yoke Assemblies are interchangeable. The yoke may be removed from the main drive shaft to be used during the test. |
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
- Install Tooling (A) on the test bench.
Illustration 4 | g01457282 |
- Install Tooling (B) to lift the transmission.
Illustration 5 | g01465949 |
Illustration 6 | g02336596 |
- Remove Brackets (1) .
Illustration 7 | g01457425 |
- Remove Cover Plate (2) and the Filter Screen (3) .
Illustration 8 | g01457650 |
Illustration 9 | g02866756 |
- Install Tooling (A) to the input end of the transmission.
Note: Use the transmission bolts that were removed in Step 3.
Illustration 10 | g01457263 |
- Use a hoist to install the transmission on the test bench. The weight of the transmission is 907 kg (2000 lb).
Illustration 11 | g02337299 |
- Install Tooling (B) to the transmission to prevent movement of the transmission during the test.
Note: Over-tightening Tooling (B) can jeopardize the tightening ability of the castle nuts on Tooling (A) later in this section.
Illustration 12 | g01457464 |
- Install Tooling (C) on the Input Shaft.
Illustration 13 | g01457442 |
- Install Tooling (D) on Tooling (C) .
Illustration 14 | g01457478 |
- Install Tooling (E) on Tooling (D) .
Illustration 15 | g01457503 |
- Install Tooling (F) on Tooling (E) .
Illustration 16 | g01457508 |
- Align the transmission to the input drive shaft.
Illustration 17 | g01457519 |
- Connect the input drive shaft to Tooling (F) .
- Install the drive shaft guard.
Illustration 18 | g01457528 |
- Tighten all four castle nuts and jack bolts.
Illustration 19 | g03802221 |
- Tighten Tooling (B) to prevent movement of the transmission during testing.
- Install Tooling (G) to the transmission case.
Illustration 20 | g02864116 |
- Remove plugs (4) .
Illustration 21 | g02864236 |
- Install Tooling (H) .
Illustration 22 | g02861158 |
- Remove cover (5) .
Illustration 23 | g02866776 |
- Connect Hose Assembly (6) from (R) to the inlet of the No. 2 flow meter.
Note: The No. 2 flow meter will measure the oil flow that is returning to the test bench from the transmission.
Illustration 24 | g02853736 |
Tooling (R) (6) To No. 2 lubrication flow meter inlet (7) From pressurized flow meter on test bench (8) To transmission control supply inlet on transmission |
- Connect Hose Assembly (7) from the pressurized flow meter to (R) .
Note: The flow meter will measure the flow of the supply oil to the transmission.
- Connect Hose Assembly (7) from Tooling (R) to Tooling (H) .
Illustration 25 | g02862936 |
(7) Control supply from Tooling (R) (8) Transmission lubrication supply from No. 2 flow meter outlet |
- Connect Hose Assembly (8) from the outlet of the No. 2 flow meter to Tooling (H) .
- Install Pressure Gauge (9) and (10) .
Illustration 26 | g02863596 |
(9) Supply pressure (10) Lubrication oil pressure |
- Install Pressure Gauges (11), (12), (13), (14) and (15) .
Illustration 27 | g02863617 |
(11) No. 5 clutch (12) No. 4 clutch (13) No. 3 clutch (14) No. 2 clutch (15) No. 1 clutch |
- Connect Tooling (M) to the transmission.
Illustration 28 | g02869282 |
- Connect Ground Clamp (16) to a suitable area.
Illustration 29 | g02863656 |
- Cover the transmission. Use a suitable clean cover.
Illustration 30 | g01457863 |
- Connect Tooling (N) to a power source. Refer to Tool Operating Manual, NEHS0644 or Tool Operating Manual, NEHS0996 for the correct operating instructions.
Illustration 31 | g00877510 |
Tooling (N) |
Illustration 32 | g01457869 |
Tooling (N) |
Test Procedure
TA3 Navigation
- Select "Dozers".
- Select "D8R-24V".
Harness Test (TA3 only)
- Make sure that the harness is properly connected.
- Use Tooling (N) to perform the harness test.
- Record the values in Table 6.
Note: Do not continue testing until Harness Test passes.
Solenoid Test (TA2 only)
- Make sure that the harness is properly connected.
- Use Tooling (N) to perform the solenoid test.
- Record the values in Table 6.
Note: Do not continue testing until Solenoid Test passes.
Start Checks
- If you are using SAE 10W oil, warm the oil to 50 °C (125 °F). Maintain this temperature for the duration of the test.
Note: Refer to Testing and Adjusting, UENR1319, "PL87 Pipelayer" for the correct adjusting procedures.
- Adjust the Input Flow to 57 ± 4 L/min (15 ± 1 US gpm).
- Check the Supply Pressure. The correct Supply Pressure is 2800 ± 100 kPa (406 ± 15 psi).
- 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.
Illustration 33 | g02720621 |
- Shift the transmission through all directions and through all speed ranges to eliminate air from the transmission controls.
- Confirm the correct clutch engagement with Table 4.
Show/hide table
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            
- The Lubrication Oil Pressure must be between 48 kPa (7 psi) and 63 kPa (9 psi).
Note: If there is no lube pressure after 3 seconds, stop input rotation and check connections on test bench and transmission.
- Record the value in Table 7.
Lubrication Circuit
- Adjust the Lubrication Oil Flow to 76 ± 4 L/min (20 ± 1 US gpm).
- Adjust the Input Rotation to 700 ± 30 rpm.
- Shift the transmission to FORWARD 2.
- Adjust the Input Rotation to 2000 ± 30 rpm.
- The Lubrication Oil Pressure must be within 7 kPa (1 psi) of the average of this arrangement. The reference is 103 ± 7 kPa (15 ± 1 psi).
- Record the value in Table 8.
Clutch Leakage Check
- Adjust the Input Flow to 114 ± 4 L/min (30 ± 1 US gpm). Maintain this flow during this check.
- Adjust the Input Rotation to 2000 ± 30 rpm in the NEUTRAL position.
- Check the Supply Pressure. The correct Supply Pressure is 2980 ± 205 kPa (432 ± 30 psi).
- Adjust the Input Rotation to 700 ± 30 rpm.
- Shift the transmission to FORWARD 1.
- Adjust the Input Rotation to 2000 ± 30 rpm.
- Record the Input Flow in Table 9.
- Record the Output Flow in Table 9.
- The leakage is obtained by subtracting the Output Flow from the Input Flow.
- Record the calculation in Table 9.
- Adjust the Input Rotation to 700 ± 30 rpm.
- 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 to REVERSE.
- 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 3.0 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
- Adjust the Input Flow to 57 ± 4 L/min (15 ± 1 US gpm).
Note: This transmission arrangement has two output speed sensors that must be tested.
- Adjust the Input Rotation to 700 ± 5 rpm.
- Shift the transmission to FORWARD 1.
- Use Tooling (P) to measure the sensor signal voltage. Measure each output speed sensor.
Illustration 34 | g01457859 |
- Record the values in Table 10.
- The voltage must be between 1 VRMS and 5 VRMS.
- Verify that both output speed sensors continue to have output.
- Record the values in Table 10.
High Idle Pressure Check
- Adjust the input flow to 114 L/min (30 US gpm).
- Adjust the input rotation to 700 ± 30 rpm.
- Shift the transmission into FORWARD 1.
- Adjust the input rotation to 2000 ± 30 rpm.
- Record the clutch pressure in Table 12.
- Repeat steps 1 through 5 for all gear ranges.
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 13.
- 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.:_______     |
Solenoid Test
Solenoid Test     | Solenoid 1     | Solenoid 2     | Solenoid 3     | Solenoid 4     | Solenoid 5     |
________ ohms |
________ ohms     |
________ ohms     |
________ ohms     |
________ ohms     |
Start Checks
Lubrication Oil Pressure     | Input Speed (700 ± 30 rpm) Input Flow 57 ± 4 L/min (15 ± 1 US gpm) Supply Pressure 2800 ± 100 kPa (406 ± 15 psi)     |
_______kPa _______(psi)     |
Lubrication Circuit
Lubrication Circuit Check     | Gear Range FORWARD 2 Input Speed (2000 ± 30 rpm) Lubrication Flow 76 ± 4 L/min (20 ± 1 US gpm)     |
||
Average Lubrication Oil Pressure Of Arrangement     | _______kPa _______(psi)     |
Lubrication Oil Pressure     | _______kPa _______(psi)     |
Clutch Leakage Check
Clutch Leakage Check     | Input Speed (2000 ± 30 rpm) Input Flow 114 ± 4 L/min (30 ± 1 US gpm) Supply Pressure 2980 ± 205 kPa (432 ± 30 psi)     |
||||||
Gear Range     | 1F     | 2F     | 3F     | 1R     | 2R     | 3R     | N     |
Input Flow     |
______     | ______     | ______     | ______     | ______     | ______     | ______     |
Output Flow     |
______     | ______     | ______     | ______     | ______     | ______     | ______     |
Leakage     |
______     | ______     | ______     | ______     | ______     | ______     | ______     |
Average of Arrangement     | ______     | ______     | ______     | ______     | ______     | ______     | ______     |
Speed Sensor Test
Speed Sensor Test     | Input Speed (700 ± 5 rpm) Input Flow 57 ± 4 L/min (15 ± 1 US gpm) Supply Pressure 2800 ± 100 kPa (406 ± 15 psi)     |
|
Sensor     | Gear Range     | |
FORWARD 1 | FORWARD 2     | |
Output Speed Sensor 1     |
__________________ VRMS     | __________________ VRMS     |
Output Speed Sensor 2     |
__________________ VRMS     | __________________VRMS     |
High Idle Pressure Check
Final Pressure Checks (High Idle)     | Input speed ( 2000 ± 30 rpm) Input flow 114 ± 4 L/min (30 ± 1 US gpm)     |
|||||
Clutch     | No. 1     | No. 2     | No. 3     | No. 4     | No. 5     | |
Speed Position     | Engaged Clutches     | Pressure (1)     | Pressure (1)     | Pressure (1)     | Pressure (1)     | Pressure (2)     |
NEUTRAL     | 3     |     |     |     |     |     |
FORWARD 1     | 2 and 5     |     | 2800 kPa (406 psi)     |
    |     | 2241 kPa (325 psi)     |
FORWARD 2     | 2 and 4     |     | 2800 kPa (406 psi)     |
    | 2800 kPa (406 psi)     |
    |
FORWARD 3     | 2 and 3     |     | 2800 kPa (406 psi)     |
2800 kPa (406 psi)     |
    |     |
REVERSE 1     | 1 and 5     | 2800 kPa (406 psi)     |
    |     |     | 2241 kPa (325 psi)     |
REVERSE 2     | 1 and 4     | 2800 kPa (406 psi)     |
    |     | 2800 kPa (406 psi)     |
    |
REVERSE 3     | 1 and 3     | 2800 kPa (406 psi)     |
    | 2800 kPa (406 psi)     |
    |     |
( 1 ) | The Tolerance is ± 100.0 kPa (± 15 psi). |
( 2 ) | The Tolerance is ± 200.0 kPa ( ± 30 psi). |
Final Pressure Checks (High Idle)     | Input speed ( 2000 ± 30 rpm) Input flow 113.5 ± 1.0 L/min (30.0 ± 0.3 US gpm)     |
|||||
Clutch     | No. 1     | No. 2     | No. 3     | No. 4     | No. 5     | |
Speed Position     | Engaged Clutches     | Pressure     | Pressure     | Pressure     | Pressure     | Pressure     |
NEUTRAL     | 3     |     |     |     |     |     |
FORWARD 1     | 2 and 5     |     |     |     |     |     |
FORWARD 2     | 2 and 4     |     |     |     |     |     |
FORWARD 3     | 2 and 3     |     |     |     |     |     |
REVERSE 1     | 1 and 5     |     |     |     |     |     |
REVERSE 2     | 1 and 4     |     |     |     |     |     |
REVERSE 3     | 1 and 3     |     |     |     |     |     |
ISO Particle Count
ISO Particle Count     | Sample the test bench oil supply.     |
________/________Particle Count     |
______________________________________ Technician     |
______________________________________ Supervisor     |