Bench Test Procedure For A 583T Pipelayer And D8T Track-Type Tractor Transmission {3030, 3073} Caterpillar

Pipelayer

583T (S/N: CMX1-UP)

Track-Type Tractor

D8T (S/N: J8B1-UP; KPZ1-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 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 questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. To address an urgent issue, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

• Knowledge Network

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, it is important 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

FT Drawings

Illustration 3	g03831077
FT-2277

Installation Procedure

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Illustration 4	g01301372

1. Install Tooling (A) to the input end of the transmission.

   Note: Use the existing transmission bolts.

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   Illustration 5	g01301376

2. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1079.5 kg (2380 lb).
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   Illustration 6	g01301381

3. Install Tooling (B) on the input shaft.
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   Illustration 7	g01301385

4. Install Tooling (C) on Tooling (B).
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   Illustration 8	g01301386

5. Install Tooling (D) on Tooling (C).
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   Illustration 9	g01301394

6. Install Tooling (E) on Tooling (D).
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   Illustration 10	g01301396

7. Align the transmission to the input drive shaft.

8. Connect the input drive shaft to Tooling (E).
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   Illustration 11	g01301474

9. Install the drive shaft guard.
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   Illustration 12	g03802221

10. Tighten all four castle nuts and jack bolts.
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    Illustration 13	g01301475

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    Illustration 14	g01301761

11. Install Tooling (F) to the transmission to prevent movement during testing.
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    Illustration 15	g01301476

12. Install Tooling (G).
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    Illustration 16	g01301477

13. Remove plug (1).
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    Illustration 17	g01301480

14. Install Tooling (H).
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    Illustration 18	g01301483

15. Remove plug (2).
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    Illustration 19	g01301495

16. Install Tooling (J).
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    Illustration 20	g01301672
    (3) Transmission Oil Supply

17. Connect hose assembly (3) from the pressurized flow meter to Tooling (G).
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    Illustration 21	g01301504
    (4) Cooler Inlet

18. Connect hose assembly (4) from Tooling (G) to the No. 2 flow meter inlet.
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    Illustration 22	g01301515
    (5) Lubrication Inlet

19. Connect hose assembly (5) from the No. 2 flow meter outlet to Tooling (G).
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    Illustration 23	g01301521
    (6) No. 1 Clutch Pressure (7) No. 2 Clutch Pressure (8) No. 3 Clutch Pressure (9) No. 5 Clutch Pressure (10) No. 4 Clutch Pressure

20. Connect pressure gauges to the appropriate locations.
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    Illustration 24	g01301532
    (11) Main Relief Valve Pressure (Supply Pressure)

21. Connect pressure gauge (11) to the appropriate location.
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    Illustration 25	g01301563
    (12) Lubrication Pressure

22. Connect pressure gauge (12) to the appropriate location.
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    Illustration 26	g01301573

23. Remove cover plate (13).
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    Illustration 27	g01301581

24. Connect Tooling (K) to the transmission.
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    Illustration 28	g01301591

25. Connect Tooling (K) to a suitable location.
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    Illustration 29	g01301607

26. Cover the transmission. Use a suitable clean cover.
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    Illustration 30	g01301605
    Tooling (L)

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    Illustration 31	g01457869
    Tooling (L)

27. Connect Tooling (L) to a power source. Refer to Tool Operating Manual, NEHS0644 for the correct operating instructions.

Test Procedure

TA3 Navigation

1. Select “Dozers”.

2. Select “D8T-24V”.

Harness Test (TA3 only)

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

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

3. Record the values in Table 6.

   Note: Do not continue testing until Harness Test passes.

Solenoid Test (TA2 only)

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 testing until Solenoid Test passes.

Start Checks

Note: Refer to Testing and Adjusting, RENR7526, "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 52 ± 4 L/min (14 ± 1 US gpm).

3. Check the supply pressure. The correct supply pressure is 2799 ± 103 kPa (406 ± 15 psi).
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   Illustration 32	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. Shift the transmission through all gears to eliminate air from the transmission controls.

6. The lubrication pressure must be at least 41 kPa (6 psi).

   Note: If there is no lube pressure after 3 seconds, stop input rotation and check connections on test bench and transmission.

7. Record the value in Table 7.

8. 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
   F1		X			X
   F2		X		X
   F3		X	X
   R1	X				X
   R2	X			X
   R3	X		X

Clutch Leakage Check

1. Adjust the input flow to 97 ± 4 L/min (26 ± 1 US gpm). Maintain this flow during this check.

2. Shift the transmission to the NEUTRAL position. Adjust the input rotation to 2100 ± 10 rpm.

3. Record the supply pressure. The correct supply pressure is 2979 ± 207 kPa (432 ± 30 psi).

4. Record the input flow in Table 8.

5. Record the output flow in Table 8.

6. The leakage is obtained by subtracting the cooler flow from the inlet flow.

7. Record the calculation in Table 8.

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

9. Shift the transmission through positions FORWARD 1, FORWARD 2, FORWARD 3, REVERSE 1, REVERSE 2, and REVERSE 3. Repeat Steps 2 through 8 for each gear range. Adjust the input rotation to 700 ± 30 rpm for all shifts.

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

10. The difference in leakage between SECOND gear and THIRD gears or between FORWARD and REVERSE should not exceed 2.3 L/min (0.6 US gpm).

11. 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 5.3 L/min (1.4 US gpm).

Lube Circuit Check

1. Adjust the input flow until the lube flow is 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 pressure must be within 9 kPa (1.3 psi) of the average for this transmission arrangement. Reference is 104 kPa (15 psi).

6. Record the value in Table 9.

Speed Sensor Test

1. Adjust the input flow to 58 ± 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 33	g01301105

4. Use Tooling (M) to measure the output speed sensor voltages at Tooling (K).

5. Record the value in Table 10.

6. The voltage must be between 1 VRMS and 5 VRMS.

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 11.

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

Transmission Bench Test Data Sheet

Solenoid/Harness Test

Start Checks

Clutch Leakage Check

Lube Circuit Check

Speed Sensor Test

Contamination Control