Bench Test Procedure for a 631K and 637K Wheel Tractor Scraper Transmission {0599, 3030, 3073} Caterpillar

Wheel Tractor-Scraper

631K (S/N: WTR1-UP; WTW1-UP)

637K (S/N: WTS1-UP; WTT1-UP; WTX1-UP; WTY1-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 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, 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

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 ? were used to develop this test procedure.

FT Drawings

Illustration 3	g06129691
FT-3319 Angle Plate

Illustration 4	g06129695
FT-3319 Assembly (A) U-Bolt (B) Angle Plate (Item 1) (C) 8M-4443 O-Ring Seal (D) 155-5077 Sleeve (Item 2) (E) 222-3725 Coupling (F) 9U-7022 Nipple (G) 1U-9585 Mounting Block Gp (H) 195-8497 Washer (J) 6V-8185 Nut

Installation Procedure

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Illustration 5	g06092955

1. Install Tooling (A) to the test bench.
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   Illustration 6	g06093040

2. Install Tooling (A) to the transmission.
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   Illustration 7	g06092961

3. Remove cover (1).
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   Illustration 8	g06093029

4. Use a hoist to install the transmission onto Tooling (A). The transmission weighs 1588 kg (3500 lb).
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   Illustration 9	g06093046

5. Install Tooling (B) to the input end of the transmission.
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   Illustration 10	g06093052

6. Install Tooling (C) onto Tooling (B).
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   Illustration 11	g06093063

7. Install Tooling (D) onto Tooling (C).
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   Illustration 12	g06093068

8. Use a hoist and pry bars to slide transmission forward to align the transmission with the input drive shaft.

9. Connect the drive shaft to Tooling (D).
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   Illustration 13	g06093075

10. Close and latch the drive shaft guard.
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    Illustration 14	g03735542

11. Tighten all four castle nuts and jack bolts.
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    Illustration 15	g06093081

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    Illustration 16	g06093079

12. Install Tooling (E) to prevent movement of the transmission during testing.
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    Illustration 17	g06093128

13. Install Tooling (F) to the output end of the transmission.
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    Illustration 18	g06093138

14. Remove bolts shown.
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    Illustration 19	g06093150

15. Install Tooling (G) to the output end of the transmission.
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    Illustration 20	g06093151

16. Use a hoist to install Tooling (H) to the output end the transmission.
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    Illustration 21	g06093153

17. Install Tooling (J) onto Tooling (H).
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    Illustration 22	g06093088

18. Remove cover (3) and plug (4).
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    Illustration 23	g06093097

19. Remove cover (5).
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    Illustration 24	g06093123

20. Remove covers (6) and (7).
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    Illustration 25	g06093165

21. Install Tooling (K).
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    Illustration 26	g06093172

22. Install Tooling (L) onto Tooling (K).
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    Illustration 27	g06093416

23. Install Tooling (M).
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    Illustration 28	g06093440

24. Install Tooling (N).
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    Illustration 29	g06093444

25. Install Tooling (P).
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    Illustration 30	g06093463

26. Install Tooling (Q).
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    Illustration 31	g06096088
    Oil Supply Photo taken off the bench for better visualization

27. Use Tooling (Q) to connect Hose Assembly (8) from Gravity Feed to the transmission oil supply port.
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    Illustration 32	g06093473
    Pump (out)

28. Connect Hose Assembly (9) from Tooling (P) to Flowmeter 1 (in).
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    Illustration 33	g06093480
    Controls (in)

29. Connect Hose Assembly (10) from Flowmeter 1 (out) to Tooling (M).
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    Illustration 34	g06093486
    Torque Converter (out)

30. Connect Hose Assembly (11) from Tooling (L) to Flowmeter 2 (in).
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    Illustration 35	g06093507
    Lube (in)

31. Connect Hose Assembly (12) from Flowmeter 2 (out) to Tooling (K).
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    Illustration 36	g06093521
    Scavenge Oil

32. Connect Hose Assembly (13) from Tooling (N) back to tank.
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    Illustration 37	g06093558
    (14) Lube Pressure (15) Torque Converter (out) Pressure

33. Connect pressure gauges (14) and (15) to Tooling (K).
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    Illustration 38	g06093607
    Controls (in) Pressure

34. Connect pressure gauge (16) to Tooling (M).
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    Illustration 39	g06093615
    (17) Clutch 4 (18) Clutch 5 (19) Clutch 6 (20) Clutch 7 (21) Clutch 3 (22) Clutch 1 (23) Clutch 2 (24) Pump Pressure (25) Torque Converter (in) Pressure

35. Connect pressure gauges to pressure taps (17-25).
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    Illustration 40	g06093623
    Spindle Drive Lube

36. Connect Hose Assembly (26) to Tooling (J).
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    Illustration 41	g06094581

37. Cover the transmission with a clean, suitable cover.
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    Illustration 42	g06094585

38. Install Tooling (R) to the transmission.
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    Illustration 43	g06094592

39. Connect Tooling (R) to Tooling (S).

Test Procedure

TA3 Navigation

1. Select "Scrapers".

2. Select "631K Front".

Harness Test

1. Make sure Tooling (R) is properly connected.

2. Use Tooling (S) to perform the Harness Test.

3. Record the values in Table 6.

   Note: Do not continue test until Harness Test passes.

Start Checks

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 during the test.
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   Illustration 44	g02720621

2. With the transmission in Neutral position, rotate the input shaft in a CLOCKWISE direction. Adjust the input rotation to 750 ± 20 rpm.

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

4. Lube pressure should be a minimum of 21 kPa (3 psi).

   Note: If there is no lube pressure after 30 seconds, stop the test and verify test stand and transmission connections.

5. Verify 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	CL7
   N				X
   F1	X					X
   F2	X				X
   F3			X			X
   F4		X				X
   F5			X		X
   F6		X			X
   F7			X	X
   F8		X		X
   R1	X						X

Low Idle Checks

1. Adjust input rotation to 750 ± 20 rpm.

2. Record Pump and Lube Flow, Pump, Controls (in), Torque Converter (in), Torque Converter (out), Lube Pressures, and Horse Power loss in Table 8.

3. Record Clutch Pressures in Table 10.

4. Confirm all values with Tables 7 and 9.

5. Repeat Steps 2 through 4 for each gear range .

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

High Idle Checks

1. Adjust input rotation to 1900 ± 20 rpm.

2. Record Pump and Lube Flow, Pump, Controls (in), Torque Converter (in), Torque Converter (out), Lube Pressures, and Horse Power loss in Table 12.

3. Record Clutch Pressures in Table 14.

4. Confirm all values with Tables 11 and 13.

5. Adjust input rotation to 750 ± 20 rpm.

6. Repeat Steps 1 through 5 for each gear range.

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

Torque Converter Block Test

1. Shift the transmission to Forward 1 position.

2. Adjust input rotation until Lube Flow is 38 ± 4 L/min (10 ± 1 US gpm).

3. Use Tooling (L) to momentarily block Torque Converter (out) Flow.

4. Record Torque Converter inlet pressure in Table .

   Note: To prevent running the transmission dry, the maximum block time is 10 seconds.

5. Open Tooling (L).

6. Confirm pressures with Table 15.

Lube Check

1. Shift the transmission to reverse position.

2. Adjust input flow until Lube Flow is 76 ± 4 L/min (20 ± 1 US gpm).

3. Record Lube Pressure in Table 15.

eMRV Check

1. Select "Lo P" option on TA3.

2. Record Pump Pressure in Table .

3. Confirm Pump Pressure with Table 17.

4. De-select "Lo P" on TA3.

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 18.

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

Transmission Test Bench Data Sheets

Harness Test

Low Idle Checks

High Idle Checks

Clutch Pressures

Torque Converter Block Test

Lube Check

eMRV Check

Contamination Control