- Pipelayer
- 561M (S/N: 1KW1-UP)
- Track-Type Skidder
- 527 (S/N: J681-UP; J691-UP)
- Track-Type Tractor
- D5M (S/N: 3DR1-UP; 4BR1-UP; 4JS1-UP; 5FS1-UP)
- D6M (S/N: 9ZM1-UP; 2RN1-UP; 5WR1-UP; 6LR1-UP; 2YS1-UP; 4GS1-UP)
Introduction
| Revision | Summary of Changes in REHS3609 | |
| 04 | Updated Table 2. | |
| 03 | Updated Title and added serial numbers J68 and J69. | |
| 02 | Standardized | |
© 2016 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar 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.
| Machine Model | Transmission Arrangement |
| 527 | |
| 527B |
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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| 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.
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| 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
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | Rail As | 1 | |
| Swivel Head Support Gp | 1 | ||
| Plate | 1 | ||
| Bolt (1/2-13 X 2.50 inch) | 3 | ||
| Hard Washer | 3 | ||
| B | Yoke As | 1 | |
| Yoke As | 1 | ||
| C | Drive Adapter | 1 | |
| Bolt (M10 X1.5 X 45 mm) | 4 | ||
| Washer | 4 | ||
| D | Drive Adapter As | 1 | |
| Bolt (3/8-16 X 1 inch) | 4 | ||
| Hard Washer | 4 | ||
| E | Drive Adapter (Key) | 1 | |
| Bolt (3/8-16 X .875 inch) | 4 | ||
| Hard Washer | 4 | ||
| F | Adapter | 1 | |
| Fitting As (Plain) | 2 | ||
| O-Ring Seal | 2 | ||
| Bolt (1/2-13 X 3.00 inch) | 1 | ||
| Bolt (1/2-13 X 3.50 inch) | 1 | ||
| Hard Washer | 4 | ||
| Nut | 2 | ||
| G | Link Bracket As | 4 | |
| Bolt (1/2-13 X 1.25 inch) | 2 | ||
| Bolt (1/2-13 X 2.25 inch) | 2 | ||
| Hard Washer | 6 | ||
| Nut | 3 | ||
| Load Binder As | 4 | ||
| H | Adapter | 1 | |
| O-Ring Seal | 1 | ||
| Fitting As (Plain) | 1 | ||
| Bolt (1/2-13 X 3 inch) | 2 | ||
| Hard Washer | 4 | ||
| Nut | 2 | ||
| P | Bypass Adapter | 1 | |
| Fitting As (Plain) | 1 | ||
| J | Fitting As (Quick Disconnect) | 2 | |
| O-Ring Seal | 2 | ||
| K | Hand Shift Lever Gp (Tool) | 1 | |
| L | Digital Multimeter | 1 | |
| M | Pressure Gauge (0 to 4,000 kPa (0 to 580 psi)) | 1 | |
| Coupler | 1 | ||
| N | Pressure Gauge (0 to 400 kPa (0 to 58 psi)) | 1 | |
| Coupler | 1 | ||
| (1) | This tool is required for the D5M transmission. |
| (2) | This tool is required for the D6M transmission. |
Installation Procedure
- Install Tooling (A) to the input end of the transmission.
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Illustration 4 g03858897 - Install Tooling (A) to the rear of the transmission.
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Illustration 5 g00891629 - Use a hoist to install the transmission on the test bench. The weight of the transmission is
492 kg (1085 lb) .Show/hide table
Illustration 6 g00891631 - Install Tooling (B) on the input shaft.
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Illustration 7 g00891632 - Install Tooling (C) on Tooling (B).
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Illustration 8 g00891635 - Install Tooling (D) on Tooling (C).
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Illustration 9 g00891636 - Install Tooling (E) on Tooling (D).
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Illustration 10 g00891639 - Align the transmission to the input drive shaft.
- Connect the input drive shaft to Tooling (E).
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Illustration 11 g00891640 - Install the drive shaft guard.
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Illustration 12 g03802221 - Tighten all four castle nuts and jack bolts.
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Illustration 13 g00891642 - Install Tooling (F).
Note: Install the longest bolt in the lower hole location. Use the lower bolt to attach Tooling (G).
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Illustration 14 g00891643 - Install Tooling (G) to the rear of the transmission to prevent movement during testing.
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Illustration 15 g00891644 - Install Tooling (G) to the input end of the transmission to prevent movement during testing.
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Illustration 16 g00891025 - Install Tooling (H) on the transmission case.
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Illustration 17 g00891645 - Remove plug (1).
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Illustration 18 g03858901 - Install Tooling (P).
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Illustration 19 g00891647 - Remove four plugs (2).
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Illustration 20 g00891649 - Install Tooling (J).
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Illustration 21 g00891651 - Connect hose assembly (3) from the pressurized flow meter to Tooling (F).
Note: The flow meter will measure the flow of the supply oil.
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Illustration 22 g00891652 - Connect hose assembly (4) from Tooling (G) to the No. 2 flow meter inlet.
Note: The No. 2 flow meter will measure the oil flow that is returning to the test bench.
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Illustration 23 g00891034 - Connect hose assembly (5) from the No. 2 flow meter to Tooling (H).
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Illustration 24 g00891653 (6) Main Supply Pressure
(7) Transmission Lube PressureNote: If you are using individual pressure gauges to measure the pressures, refer to Table 3 for the correct pressure gauges.
- Connect pressure gauge (6) to Tooling (J).
- Connect pressure gauge (7) to Tooling (J).
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Illustration 25 g00891654 (8) Speed Clutch Pressure "P1"
(9) Direction Clutch Pressure "P2" - Connect pressure gauge (8) to Tooling (J).
- Connect pressure gauge (9) to Tooling (J).
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Illustration 26 g00891655 - Install Tooling (K) on the transmission.
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Illustration 27 g00891656 - Cover the transmission. Use a suitable clean cover.
Note: Make sure that the transmission is secured to the test bench. Tighten all bolts to the proper torque.
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| Illustration 3 | g00891627 |
Start Checks
- 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 to34 °C (95 °F) . Maintain this temperature during the test. - If you are testing a D5M or a 561M transmission, then adjust the input flow to
34 ± 4 L/min (9 ± 1 US gpm) . If you are testing a D6M transmission, then adjust the input flow to30 ± 4 L/min (8 ± 1 US gpm) .Show/hide table
Illustration 28 g02720621 - With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 850 ± 30 rpm.
Note: The input shaft will be rotated in a counterclockwise direction during this test. The direction is determined as you face the drive motor of the test bench.
- Shift the transmission through all directions and through all speed ranges to eliminate air from the transmission controls.
- Check for lockup or excessive drag in all speed ranges.
- Stop the input shaft.
Note: Refer to Testing and Adjusting, SENR9466, "D5M Track-Type Tractor Power Train", Testing and Adjusting, SENR9481, "D6M Track-Type Tractor Power Train", or Testing and Adjusting, SENR1755, "561M Pipelayer" for the correct adjusting procedures.
Initial Pressure Check
- Remove load piston plug (10) from the top of the transmission control valve.
- If you are testing a D5M or a 561M transmission, then adjust the input flow to
34 ± 4 L/min (9 ± 1 US gpm) . If you are testing a D6M transmission, then adjust the input flow to30 ± 4 L/min (8 ± 1 US gpm) . - With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 850 ± 30 rpm.
- The "P1" pressure must be
531 ± 34 kPa (77 ± 5 psi) . - Stop the input rotation.
- Stop the input flow.
- Install load piston plug (10).
- Record the value in Table 6.
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| Illustration 29 | g00891657 |
Neutralizer Valve Check
- Shift the transmission to FORWARD 3.
- If you are testing a D5M or a 561M transmission, then adjust the input flow to
34 ± 4 L/min (9 ± 1 US gpm) . If you are testing a D6M transmission, then adjust the input flow to30 ± 4 L/min (8 ± 1 US gpm) . - Adjust the input rotation to 850 ± 30 rpm. The "P2" pressure must be
0 kPa (0 psi) . - Adjust the input flow to
80 ± 4 L/min (21 ±1 US gpm) . - Adjust the input rotation to 2000 ± 30 rpm if you are testing a D5M or a 561M transmission. Adjust the input rotation to 2200 ± 30 rpm if you are testing a D6M transmission. The "P2" pressure must be
0 kPa (0 psi) . - Shift the transmission to NEUTRAL and then shift the transmission to any speed range. The "P2" pressure must rise to normal pressure. The normal pressure is determined by subtracting
379 ± 55 kPa (55 ± 9 psi) from the "P1" pressure. - Record the value in Table 7.
Clutch Leakage Check
- Adjust the input flow to
79.5 ± 4 L/min (21 ± 1 US gpm) . Maintain this flow during this check. - Adjust the input rotation to 500 ± 30 rpm.
- Shift the transmission to FORWARD 1.
- Adjust the input rotation to 2000 ± 30 rpm if you are testing a D5M or a 561M transmission. Adjust the input rotation to 2200 ± 30 rpm if you are testing a D6M transmission.
- Record the input flow in Table 8.
- Record the output flow in Table 8.
- The leakage is obtained by subtracting the output flow from the input flow.
- Record the calculation in Table 8.
- Adjust the input rotation to 500 ± 30 rpm.
- Shift the transmission through positions FORWARD 2, FORWARD 3, REVERSE 1, REVERSE 2, REVERSE 3, and NEUTRAL. Repeat Steps 3 through 9 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
6.8 ± 3 L/min (1.8 ± 0.8 US gpm) of the average for this arrangement.
Lube Circuit Check
- Shift the transmission to FORWARD 2.
- Adjust the input flow until the lube flow is
57 ± 4 L/min (15 ± 1 US gpm) . - Adjust the input rotation to 2000 ± 30 rpm if you are testing a D5M or a 561M transmission. Adjust the input rotation to 2200 ± 30 rpm if you are testing a D6M transmission.
- The lube pressure must be
76 ± 7 kPa (11 ± 1 psi) . - Record the value in Table 9.
Transmission Bench Test Data Sheet
| CATERPILLAR | Transmission Bench Test Data Sheet | Test Date:_______ |
| Model:_______ | ||
| Work Order:_______ | Serial No.:_______ | |
Specifications
| General Specifications | ||
| Description | High Idle | Low Idle |
| Input Speed | D5M and 561M
2000 ± 30 rpm D6M 2200 ± 30 rpm |
850 ± 30 rpm |
| Input Flow | |
|
| Minimum Lube Flow | |
|
| Pressures | ||
| "P1" Initial(1) | |
|
| P1 | |
|
| P2 | |
|
| P3(2) | |
|
| Lube(3) | |
|
| (1) | The load piston plug is removed and the transmission is in the NEUTRAL position. |
| (2) | The flow for the converter outlet is restricted. |
| (3) | The transmission is in FORWARD 2. |
Initial Pressure Check
| Initial Pressure | Input Speed (850 ± 30 rpm)
Input Flow |
_______kPa _______(psi) |
||||
Neutralizer Valve Check
| Neutralizer Valve | |||
| Input Flow | Input Speed | Gear Range | "P2" Pressure |
| |
850 ± 30 rpm | FORWARD 3 | _______kPa _______(psi) |
| |
2000 ± 30 rpm(1)
2200 ± 30 rpm(2) |
FORWARD 3 | _______kPa _______(psi) |
| NEUTRAL then shift to any gear range. | _______kPa _______(psi) |
||
| (1) | D5M or 561M specification |
| (2) | D6M specification |
Clutch Leakage Check
| Clutch Leakage Check | Input Speed "D5M" and 561M (2000 ± 30 rpm)
Input Speed "D6M" (2200 ± 30 rpm) Input Flow |
||||||
| Gear Range | 1F | 2F | 3F | 1R | 2R | 3R | N |
| Input Flow | ______ | ______ | ______ | ______ | ______ | ______ | ______ |
| Output Flow | ______ | ______ | ______ | ______ | ______ | ______ | ______ |
| Leakage | ______ | ______ | ______ | ______ | ______ | ______ | ______ |
| Average of Arrangement | ______ | ______ | ______ | ______ | ______ | ______ | ______ |
Lube Circuit Check
| Lube Circuit Check | Gear Range FORWARD 2
Input Speed "D5M" (2100 ± 30 rpm) Input Speed "D6M" (2200 ± 30 rpm) Input Flow |
||
| Average Lube Pressure Of Arrangement | _______kPa _______(psi) |
Lube Pressure | _______kPa _______(psi) |
ISO Particle Count
| ISO Particle Count | Sample the test bench oil supply. | ________/________Particle Count |
______________________________________ Technician |
______________________________________ Supervisor |