Bench Test Procedure For A 814B Wheel Dozer, 815B Soil Compactor, and 816B Landfill Compactor Transmission {3030, 3073} Caterpillar

Landfill Compactor

816B (S/N: 15Z1-UP)

Soil Compactor

815B (S/N: 17Z1-UP)

Wheel Dozer

814B (S/N: 16Z1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS2274
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
814B	8P-2184
815B	7G-2093
816B	8P-2184

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
	FT0709	Support	1
	6V-2156	Link Bracket	2
B	FT1073	Spacer Ring	1
	FT1081	Drive Ring	1
C	FT1075	Drive Adapter	1
D	FT1396	Torque Converter Cover	1
E	FT0698	Drive Adapter	1
	FT0699	Retention Plate	1
	FT0697	Key	1
F	1U-9722	Load Binder As (Ratchet Type)	3
G	1U-8304	Fitting	1
	9U-7446	Adapter	1
	1P-4577	Half Flange	2
	8C-9024	Nipple (Plain)	1
	6V-3965	Nipple (Quick Disconnect)	1
	6V-1820	Bolt (M10X1.5X30 mm)	4
	6V-5839	Washer	4
H	1U-8304	Fitting	1
	9U-7446	Adapter	1
	1P-4577	Half Flange	2
	8C-9024	Nipple (Plain)	1
	6V-3965	Nipple (Quick Disconnect)	1
	6V-1820	Bolt (M10X1.5X30 mm)	4
	6V-5839	Washer	4
X	3B-7749	Nipple (Close)	1
	4B-7770	Tee (Pipe)	1
	6B-1628	Reducing Bushing	1
	3B-7722	Reducing Bushing	1
	7S-8887	Nipple (Quick Disconnect)	1
	8C-9024	Nipple (Plain)	1
	1U-9851	Flange Assembly	1
	6V-1820	Bolt (M10X1.5X30 mm)	4
	6V-5839	Washer	4
J	1U-8301	Fitting	1
	9U-7445	Adapter	1
	1P-4578	Half Flange	2
	8C-9024	Nipple (Plain)	1
	6V-3965	Nipple (Quick Disconnect)	1
	4J-0524	O-Ring Seal	1
	6V-8197	Bolt (M12X1.75X40 mm)	4
	5P-8245	Washer	4
K	120-6843	Ball Valve	1
	7F-6654	Nipple (Pipe)	2
	6B-9081	Reducing Bushing	2
	7X-7646	Nipple (Quick Disconnect)	1
	8C-9025	Coupler (Quick Disconnect)	1
L	1U-9879	Nipple (Quick Disconnect)	1
	3N-8699	Reducing Bushing	1
	5B-7660	Reducing Bushing	1
	6L-7349	Nipple (Pipe)	1
	5B-7666	Street Elbow	1
	1U-9857	Flange Assembly	1
	8T-6430	Bolt (M20X2.50X50 mm)	2
	8T-4123	Washer	2
M	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
N	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
P	7S-8890	Nipple (Quick Disconnect)	1
	3B-7282	Nipple (Pipe)	1
Q	6V-4821	Test Cover	1
R	7S-8887	Nipple (Quick Disconnect)	1
	5P-3501	Adapter	1
	3J-1907	O-Ring Seal	1
S	5M-1152	Cover	1
T	FT1551	Shift Lever	1
U	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	3
	6V-4144	Coupler	3
V	8T-0854	Pressure Gauge (0 to 1,000 kPa (0 to 145 psi))	2
	6V-4144	Coupler	2
W	8T-0862	Pressure Gauge (-100 to 500 kPa (-15 to 72 psi))	1
	6V-4144	Coupler	1

FT Drawings

Illustration 3	g06023613
FT-0697

Illustration 4	g06023616
FT-0699

Illustration 5	g06023614
FT-0698

Illustration 6	g06023655
FT-0709

Illustration 7	g06023662
FT-1075 (Part 1) (A) 23.1 mm (0.91 inch) (B) 15.7 mm (0.62 inch) (C) 12.7 mm (0.5 inch) (D) ø 11.91 mm (0.469 inch)8 holes equally spaced (E) ø 352.43 ± 0.05 mm (13.875 ± 0.002 inch) (F) ø 95.25 mm (3.75 inch) (G) ø 76.3 ± 0.08 mm (3.004 ± 0.003 inch) (H) 13.08 ± 0.13 mm (..315 ± 0.005 inch) (J) 27.94 ± 0.13 mm (1.1 ± 0.005 inch) (K) 15º (L) ø 101.6 mm (4 inch) (M) ø 55 ± 0.008 mm (2.17 ± 0.0003 inch) (N) ø 35 ± 0.08 mm (1.38 ± 0.003 inch) (P) 65º (Q) 4.8 mm (0.19 inch) (R) 12.7 mm (0.5 inch) (S) 25.37 ± 0.03 mm (0.999 ± 0.001 inch) (T) 72.64 mm (2.86 inch) (U) 102.9 mm (4.05 inch)

Illustration 8	g06023663
FT-1075 (Part 2) (A) 8.33 ± 0.08 mm (328 ± 0.003 inch) (B) 6.198 ± 0.038 mm (0.244 ± 0.0015 inch) (C) 3.1 mm (0.122 inch) (D) ø 368.3 mm (14.5 inch) (E) ø 333.38 mm (13.125 inch)

Illustration 9	g06023621
FT-1073

Illustration 10	g06023628
FT-1081

Illustration 11	g06023635
FT-1396 (Part 1)

Illustration 12	g06023640
FT-1396 (Part 2) (E) 2P-8102 Roller Bearing As

Illustration 13	g06034822
FT-1551

Illustration 14	g06034829
FT-1551 (Assembly) (1) Item 1 Bracket As. Qty: 1 (2) Item 2 Block Qty: 2 (3) Item 3 Pin Qty: 4 (4) Item 4 Rod Qty: 2 (5) Item 5 Lever Qty: 2 (6) Item 6 Boss Qty: 2 (7) Item 7 Lever As. Items 4, 5, and 6 Qty: 2 (8) 2G-0111 Knob Qty: 2 (9) 9S-7381 Bolt Qty: 2 (10) Item 10 Link Qty: 2

Installation Procedure

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Illustration 15	g01208220

1. Install Tooling (A) to support the transmission.
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   Illustration 16	g00993298
   Typical Example

2. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1001 kg (2206 lb).
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   Illustration 17	g01208351

3. Install Tooling (B).

4. Install Tooling (C).
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   Illustration 18	g01208357

5. Install Tooling (D).
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   Illustration 19	g01208363

6. Install Tooling (E).
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   Illustration 20	g01208372

7. Remove the cover, the suction screen, and the magnetic strainer (1).

   Note: This will allow the oil to drain into the sump tank.

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   Illustration 21	g01208375
   Typical Example

8. Align the transmission with the input drive shaft.

9. Connect the input drive shaft to Tooling (E).
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   Illustration 22	g01208376

10. Install the drive shaft guard.
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    Illustration 23	g03802221

11. Tighten all four castle nuts and jack bolts.
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    Illustration 24	g01208387

12. Fasten the transmission to the test bench by using Tooling (F).
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    Illustration 25	g01208437
    (L) Gravity Feed

13. Install Tooling (L).
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    Illustration 26	g01208425

14. Install Tooling (H).
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    Illustration 27	g01208422

15. Install Tooling (G).
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    Illustration 28	g01208428

16. Install Tooling (J).
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    Illustration 29	g01208434

17. Install Tooling (K) to Tooling (J).
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    Illustration 30	g03123299

18. Install Tooling (X).
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    Illustration 31	g06013820
    (2) Oil Supply to the Transmission

19. Connect hose assembly (2) from main oil supply (gravity feed) to Tooling (L).
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    Illustration 32	g06013822
    (3) Pump Outlet

20. Connect hose assembly (3) from Tooling (H) to the No. 1 flow meter inlet.
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    Illustration 33	g06014363

21. Connect hose assembly (4) from the No. 1 flow meter outlet to Tooling (G).
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    Illustration 34	g06013829
    (5) Torque Converter Outlet Oil

22. Connect hose assembly (5) from Tooling (K) to the No. 2 flow meter inlet.
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    Illustration 35	g06013834
    (6) Lubrication Oil Supply

23. Connect hose assembly (6) from the No. 2 flow meter outlet to Tooling (X).
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    Illustration 36	g01208468

24. Remove the cover from the top of the transmission.

25. Remove the pipe plugs from the "P1", "P2", and "P3" pressure taps in the top of the control valve.

26. Install Tooling (M).
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    Illustration 37	g01208476

27. Install Tooling (N).
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    Illustration 38	g01208477

28. Install Tooling (P).
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    Illustration 39	g01208482

29. Install Tooling (Q).
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    Illustration 40	g01208485
    (6) Speed Clutch Pressure "P1"

    Note: If you are using individual pressure gauges to measure the pressure, refer to Table 3 for the correct pressure gauges.

30. Connect a pressure line (6) to Tooling (M).
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    Illustration 41	g01208490
    (7) Directional Clutch Pressure "P2"

31. Connect a pressure line (7) to Tooling (N).
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    Illustration 42	g01208494
    (8) Torque Converter Inlet Pressure "P3"

32. Connect a pressure line (8) to Tooling (P).
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    Illustration 43	g01208500
    (9) Lubrication Pressure

33. Connect a pressure line (9) to Tooling (X).
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    Illustration 44	g01208505

34. Install Tooling (R).
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    Illustration 45	g01208506
    (10) Torque Converter Outlet Pressure

35. Connect a pressure line (10) to Tooling (R).
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    Illustration 46	g01208511

36. If the hydraulic pump is still mounted on the transmission, remove the pump and install Tooling (S).
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    Illustration 47	g01208519

37. Install Tooling (T).

Test Procedure

Start Checks

Note: Refer to Testing and Adjusting, SENR2207-00, "814B Tractor, 815F Soil Compactor, and 816F Landfill Compactor 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.
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   Illustration 48	g02720621

2. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 630 ± 50 rpm.

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

4. 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
   N			X
   F1		X				X
   F2		X			X
   F3		X		X
   F4		X	X
   R1	X					X
   R2	X				X
   R3	X			X
   R4	X		X

5. Stop the input rotation.

Initial Pressure

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Illustration 49	g01208521

1. Remove the load piston plug (11) from the top of the controls.

2. Shift the transmission to NEUTRAL.

3. Adjust the input rotation to 630 ± 50 rpm.

4. The initial "P1" clutch pressure must be 531 ± 34 kPa (77 ± 5 psi).

5. Record the value in Table 7.

6. Stop the input rotation.

7. Install the load piston plug (11).

Pressure Differential Valve

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

2. Adjust the input rotation to 2140 ± 80 rpm.

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

4. Shift the directional 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 630 ± 50 rpm.

2. Shift the transmission to FORWARD 1.

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

4. The "P3" torque converter inlet pressure must be 896 ± 82 kPa (130 ± 12 psi).

5. Open the lube flow.

6. Record the value in Table 9.

Lube Circuit Check

1. Shift the transmission to FORWARD 3.

2. Adjust the input rotation until the lube flow is 76 ± 4 L/min (20 ± 1 US gpm). Maintain this flow during this check.

3. The lubrication pressure must be 220 ± 7 kPa (32 ± 1 psi).

4. Record the value in Table 10.

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

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	2140 ± 80 rpm	630 ± 50 rpm
Input Flow	114 ± 4 L/min (30 ± 1 US gpm)	30 ± 4 L/min (8 ± 1 US gpm)
Pressures
"P1" Initial (1)	-	531 ± 34 kPa (77 ± 5 psi)
"P1"	2580 ± 138 kPa (374 ± 20 psi)	2206 kPa (320 psi) Minimum
"P2"	P1- 379 ± 55 kPa (P1- 55 ± 8 psi)	P1- 379 ± 55 kPa (P1- 55 ± 8 psi)
"P3" (2)	593 ± 41 kPa (86 ± 6 psi)	896 ± 82 kPa (130 ± 12 psi)
Torque Converter Outlet (Reference)	455 ± 48 kPa (66 ± 7 psi)	345 ± 55 kPa (50 ± 8 psi)
Lube (Reference)	303 ± 41 kPa (44 ± 6 psi)	7 kPa (1 psi) Minimum

(1)	The load piston plug (11) 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

Table 7

"P1" Clutch Pressure

Input Speed (630 ± 50 rpm) Gear Range NEUTRAL Removed Load Piston Plug (11)

_______kPa _______(psi)

Pressure Differential Valve

Table 8

"P2" Directional Clutch Pressure	Input Speed (2140 ± 80 rpm)
Any Gear Range (Excluding NEUTRAL)	_______kPa _______(psi)
Gear Range NEUTRAL	_______kPa _______(psi)

Torque Converter Inlet Relief Valve

Table 9

"P3" Torque Converter Inlet Pressure

Input Speed (630 ± 50 rpm) Gear Range FORWARD 1 Restricted Torque Converter Outlet

_______kPa _______(psi)

Lube Circuit Check

Table 10

Lube Pressure

Gear Range FORWARD 3 Lube Flow 76 ± 4 L/min (20 ± 1 US gpm)

_______kPa _______(psi)

Contamination Control

Table 11

ISO Particle Count

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

________/________Particle Count

Table 12

______________________________________ Technician

______________________________________ Supervisor