Bench Test Procedure for an 814K, 815K, and 816K Compactor Transmission {0374, 0599, 0720, 3030, 3064, 3073} Caterpillar

Landfill Compactor

816K (S/N: LT61-UP; WNB1-UP; SLL1-UP; WCL1-UP)

Soil Compactor

815K (S/N: SL91-UP; MBB1-UP; WCS1-UP; T1Y1-UP)

Wheel Dozer

814K (S/N: LW41-UP; DMB1-UP; WCM1-UP; T1Z1-UP)

Introduction

© 2018 Caterpillar All Rights Reserved. This document 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 document 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 document 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 document 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.

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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 document 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. These tools are suggested and may very depending on availability and bench configuration.

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159-0747 Crossmember modification (A) () (B) ()

Installation Procedure

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1. Install Tooling (A) to the test stand.
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2. Using a hoist, install the transmission to Tooling (A) using Tooling (B). The weight of the transmission is 1134 kg (2500 lb).
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3. Install Tooling (C).
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4. Install Tooling (D) to the input end of the transmission.
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5. Install Tooling (E).
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6. Install Tooling (F) to Tooling (E).
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7. Install Tooling (G) onto Tooling (F).
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8. Install Tooling (H) onto Tooling (G).
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9. Using a hoist, align the transmission with the input drive shaft.
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10. Tighten all four castle nuts and jack bolts.
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11. Install Tooling (K) to both ends of the transmission to prevent movement during testing.
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12. Remove Tube (1).
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13. Install Tooling (L).
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14. Install Tooling (M) and (N).
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15. Install Tooling (P).
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16. Install Tooling (Q) to Tooling (P).
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17. Install Tooling (R).
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    Gravity Feed

18. Connect Hose Assembly (2) from oil supply to Tooling (L)
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    Pump (out)

19. Connect Hose Assembly (3) from Tooling (M) to Flowmeter 1 (in).
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    Controls/Torque Converter (in)

20. Connect Hose Assembly (4) from Flowmeter 1 (out) to Tooling (N).
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    Controls/Torque Converter (out)

21. Connect Hose Assembly (5) from Tooling (Q) to Flowmeter 2 (in).
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    Lube (in)

22. Connect Hose Assembly (6) from Flowmeter 2 (out) to Tooling (R).
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    Spindle Lube

23. Connect Hose Assembly (7) to Tooling (F).
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    (8) Clutch 6 (9) Clutch 5 (10) Clutch 4 (11) Clutch 3 (12) Clutch 2 (13) Clutch 1

24. Connect Pressure Gauges to Pressure Taps (8-13).
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    Lube Pressure

25. Connect Pressure Gauge (14) to Tooling (R).
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    Torque Converter (out) Pressure

26. Connect a Pressure Gauge to Pressure Tap (15).
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    (16) Controls Pressure (17) Torque Converter (in) Pressure

27. Connect Pressure Gauges to Pressure Taps (16) and (17).
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    Pump Pressure

28. Connect Pressure Gauge (18) to Tooling (M).
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29. Install Tooling (S) to the transmission.
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30. Connect Tooling (S) to Tooling (T). Refer to Tool Operating Manual , NEHS0996 for the correct operating instructions.

Test Procedure

TA3 Navigation

1. Select "Compactors".

2. Select "814K", "815K", or "816K".

Harness Test

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

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

3. Record the values in Table 6.

   Note: Do not continue testing until Harness Test passes.

Start Check

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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2. With the transmission in neutral position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 900 ± 20 rpm.

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

4. The lube pressure should be minimum 28 kPa (4 psi).

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

5. Confirm the correct clutch engagement with Table 4.
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   Table 4

   Clutch Engagement Check
   Gear	Direction Clutches		Speed Clutches
   	CL 1	CL 2	CL 3	CL 4	CL 5	CL 6
   N			X
   F1		X				X
   F2		X			X
   F3		X		X
   R1	X					X
   R2	X				X
   R3	X			X

6. Measure Pump Flow, Lube Flow, Pump Pressure, TC inlet Pressure, TC outlet Pressure, Main Relief Pressure and Lube Pressure. Record values in Table 8.

7. Confirm values with Table 7.

8. Increase input speed to 2270 ± 20 rpm.

9. Repeat Steps 6 and 7.

Torque Converter Block Test

1. With the transmission in neutral position, adjust the input rotation to 900 ± 20 rpm.

2. Shift the transmission into forward 1 position.

3. Use Tooling (Q) to block flow temporarily.

4. Record Torque Converter inlet and outlet pressures in Table 9.

5. Confirm values in Table 9.

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

6. Open lube flow.

Lube Circuit Check

1. Shift the transmission to Forward 3.

2. Adjust the input rotation to achieve a Lube Flow of 76 ± 4 L/min (20 ± 1 US gpm).

3. Lube Pressure must be 179 ± 28 kPa (26 ± 4 psi).

4. Record the value in Table 10.

Low Idle Checks

1. Adjust the input rotation to 900 ± 20 rpm.

2. Shift the transmission to forward 1.

3. Record Pump Flow, Lube Flow, Pump Pressure, TC inlet Pressure, TC outlet Pressure, Main Relief Pressure, and Lube Pressure in Table 12.

4. Confirm values with Table 11.

5. Record all clutch pressures in Table 14.

6. Confirm values with Table 13.

7. Shift transmission through all gears and repeat Steps 3 through 6.

High Idle Checks

1. Adjust the input rotation to 900 ± 20 rpm.

2. Shift the transmission to forward 1.

3. Adjust the input rotation to 2270 ± 20 rpm.

4. Record Pump Flow, Lube Flow, Pump Pressure, TC inlet Pressure, TC outlet Pressure, Main Relief Pressure, Lube Pressure, and Horse Power Loss in Table 16.

5. Confirm values with Table 15.

6. Record all clutch pressures in Table 18.

7. Confirm values with Table 17.

8. Adjust the input rotation to 900 ± 20 rpm.

9. Shift transmission through all gears and repeat Steps 3 through 1.

Speed Sensor Test

1. Adjust the input rotation to 900 ± 20 rpm.

2. Shift the transmission to forward 2.

3. Record Output Speed 1, Output Speed 2, and TC Output Speed in Table 19.

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 20.

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

Transmission Bench Test Data Sheet

Harness Test

Start Check

Torque Converter Block Test

Lube Circuit Test

Low Idle Checks

High Idle Checks

Speed Sensor Test

Contamination Control