Bench Test Procedure For A 613 And 613B Wheel Tractor-Scraper Transmission {3030, 3073} Caterpillar

Wheel Scraper

613 (S/N: 72M1-UP)

613B (S/N: 72M1-UP)

Wheel Tractor

613 (S/N: 71M1-UP)

613B (S/N: 38W1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS3185
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 issue, 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
613B	8S-3543
613	8S-3543

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 often used to compare values on portions of transmission tests. 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.

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9584	Rail As	2
	1U-9585	Mounting Block Gp	1
	FT-0908	Support	1
B	FT-0912	Adapter (Input Flange)	1
C	1U-9722	Ratcheting Turnbuckle	3
D	1U-8305	Adapter	1
	1P-4577	Split Flange	2
	8C-9024	Nipple (Plain)	1
E	1U-8303	Adapter (Elbow)	1
	1P-4577	Split Flange	2
	8C-9024	Nipple (Plain)	1
	8C-9025	Coupler (Quick Disconnect)	1
	7X-7646	Nipple (Plain)	1
	6B-9081	Bushing (Reducing)	2
	7F-6654	Nipple (Pipe)	2
	267-8926	Needle Valve	1
F	1U-9852	Flange Assembly	1
G	7S-8887	Nipple (Quick Disconnect)	1
	5P-3501	Adapter	1
	3J-0907	Seal	1
H	7S-8887	Nipple (Quick Disconnect)	1
	5P-3501	Adapter	1
	3J-0907	Seal	1
J	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
K	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
L	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
M	9S-9070	Test Cover	1
N	2M-3916	Lever	2
	7F-8092	Knob	2

FT Drawings

Illustration 3	g06055987
FT-0912

Illustration 4	g06055976
FT-0908

Installation Procedure

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Illustration 5	g01256783

1. Install Tooling (A).
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   Illustration 6	g01257687
   Typical Example

2. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1516.8 kg (3344 lb).
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   Illustration 7	g01256812
   Typical Example

3. Install Tooling (B).
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   Illustration 8	g01256814
   Typical Example

4. Align the transmission with the input drive shaft.

5. Connect the input drive shaft with Tooling (B).
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   Illustration 9	g01256815
   Typical Example

6. Install the drive shaft guard.
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   Illustration 10	g03802221

7. Tighten all four castle nuts and jack bolts.
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   Illustration 11	g01256845
   Typical Example

8. Install Tooling (C) on the input end of the transmission.
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   Illustration 12	g01256825

9. Install Tooling (C) on the output end of the transmission.
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   Illustration 13	g01256856
   Typical Example

10. Remove cover (1) to drain oil from the transmission.
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    Illustration 14	g01257250

11. Install Tooling (D).
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    Illustration 15	g01257253

12. Install Tooling (E).
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    Illustration 16	g01257272

13. Install Tooling (F).
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    Illustration 17	g01257278

14. Install Tooling (G).
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    Illustration 18	g01257288

15. Install Tooling (H).
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    Illustration 19	g01257334
    (2) Transmission Inlet

16. Connect hose assembly (2) from the outlet of the pressurized flow meter to Tooling (D).
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    Illustration 20	g01257348
    (3) Torque Converter Outlet

17. Connect hose assembly (3) from Tooling (E) to the No. 2 flow meter inlet.
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    Illustration 21	g01257337
    (4) Lubrication Inlet

18. Connect hose assembly (4) from the No. 2 flow meter outlet to Tooling (F).
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    Illustration 22	g01257363
    (5) Oil Pump Pressure

19. Connect pressure gauge (5) to Tooling (G).
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    Illustration 23	g01257367
    (6) Lubrication Pressure

20. Connect pressure gauge (6) to Tooling (H).
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    Illustration 24	g01257290

21. Install Tooling (J).
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    Illustration 25	g01257312

22. Install Tooling (K).
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    Illustration 26	g01257315

23. Install Tooling (L).
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    Illustration 27	g01257331

24. Install Tooling (M).
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    Illustration 28	g01257324

25. Install Tooling (N).
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    Illustration 29	g01257369
    (7) Speed Clutch And Initial Pressure "P1"

26. Connect pressure gauge (7) to Tooling (J).
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    Illustration 30	g01257372
    (8) Directional Clutch Pressure "P2"

27. Connect pressure gauge (8) to Tooling (K).
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    Illustration 31	g01257375
    (9) Torque Converter Inlet Pressure "P3"

28. Connect pressure gauge (9) to Tooling (L).

Test Procedure

Start Checks

Note: Refer to Testing and Adjusting, SENR7306, "613B Wheel 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 input flow to 27 L/min (7 US gpm).
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   Illustration 32	g02720621

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 675 ± 30 rpm.

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

5. 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	Cl 6
   NN				X
   NF				X
   NR				X
   F1			X			X
   F2			X		X
   F3			X	X
   F4	X				X
   R1		X				X
   R2		X			X
   R3		X		X

6. Stop the input rotation.

Initial Pressure

1. Remove the load piston plug from the top of the controls.

2. Shift the transmission to NEUTRAL.

3. Adjust the input rotation to 675 ± 30 rpm.

4. The initial "P1" clutch pressure must be 517 ± 34 kPa (75 ± 5 psi).

5. Record the value in Table 7.

6. Stop the input rotation.

7. Install the load piston plug.

Safety Valve

1. Place the direction selector in a position that is not NEUTRAL.

2. Adjust the input rotation to 675 ± 30 rpm.

3. The "P2" directional clutch pressure must remain at zero.

4. Shift the direction selector to NEUTRAL.

5. The "P2" directional clutch pressure must rise to normal pressure.

6. Record the values in Table 8.

Torque Converter Inlet Relief Valve

1. Adjust the input rotation to 675 ± 30 rpm.

2. Shift the transmission to FORWARD 1.

3. Use Tooling (F) to momentarily block the flow at the torque converter outlet.

4. The "P3" torque converter inlet pressure must be 724 ± 34 kPa (105 ± 5 psi).

5. Open the lube flow.

6. Record the value in Table 9.

Lube Circuit

1. Shift the transmission to FORWARD 2.

2. Adjust the input rotation until the lube flow is 42 ± 4 L/min (11 ± 1 US gpm). Maintain this flow during this check.

3. The lubrication pressure must be 90 ± 14 kPa (13 ± 2 psi).

4. Record the value in Table 10.

Clutch Leakage

1. Measure the leakage in each gear at 2200 ± 30 rpm.

   Note: The leakage is obtained by subtracting the lube flow from the input flow.

2. The lube flow in FORWARD 1 and REVERSE must not exceed 6.4 L/min (1.7 US gpm) less than all other ranges.

3. The leakage difference between FORWARD 2 gear range and FORWARD 3 gear range must not exceed 3.8 L/min (1 US gpm).

4. The leakage difference between FORWARD 4 and all other gear ranges must not exceed 5.7 L/min (1.5 US gpm).

5. Record the values in Table 11.

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 5

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

Specifications

Table 6

Specifications
Description	High Idle	Low Idle
Input Speed	2200 ± 5 rpm	675 ± 30 rpm
Input Flow	95 L/min (25 US gpm)	27 L/min (7 US gpm)
Minimum Lube Flow	80 L/min (21 US gpm)	-
Pressures
"P1" Initial (1)	-	517 ± 34 kPa (75 ± 5 psi)
"P1" Pressure	2172 ± 69 kPa (315 ± 10 psi)	1931 kPa (280 psi) Minimum
"P2" Pressure	P1 - 345 ± 55 kPa (P1 - 50 ± 8 psi)	P1 - 345 ± 55 kPa (P1 - 50 ± 8 psi)
"P3" Pressure	-	724 ± 34 kPa (105 ± 5 psi) (2)
Lubrication Pressure	90 ± 21 kPa (13 ± 3 psi)	28 ± 14 kPa (4 ± 2 psi) Minimum

(1)	The load piston plug (13) is removed and the transmission is in NEUTRAL.
(2)	The torque converter oil flow is blocked and the transmission is in FORWARD 1.

Initial Pressure Check

Table 7

"P1" Clutch Pressure

Input Speed (675 ± 30 rpm) Gear Range NEUTRAL Removed Load Piston Plug

_______kPa _______(psi)

Safety Valve

Table 8

"P2" Directional Clutch Pressure	Input Speed (675 ± 30 rpm)
Any Gear Range Except NEUTRAL	_______kPa _______(psi)
Gear Range NEUTRAL	_______kPa _______(psi)

Torque Converter Inlet Relief Valve

Table 9

"P3" Torque Converter Inlet Pressure

Input Speed (675 ± 30 rpm) Gear Range FORWARD 1 Restricted Torque Converter Outlet

_______kPa _______(psi)

Lube Circuit Check

Table 10

Lube Pressure

Gear Range FORWARD 2 Input Flow 42 ± 4 L/min (11 ± 1 US gpm)

_______kPa _______(psi)

Clutch Leakage Check

Table 11

Clutch Leakage Check				Input Speed (2200 ± 30 rpm)
Gear Range	NN	NR	NF	F1	F2	F3	F4	R1	R2	R3
Input Flow
Lube Flow
Leakage

Contamination Control

Table 12

ISO Particle Count

Sample the test bench oil supply. *ISO 4406 is 16/13 or better

________/________Particle Count

Table 13

______________________________________ Technician

______________________________________ Supervisor