Bench Test Procedure for a 627H, 627K, and 637K Wheel Tractor-Scraper Rear Transmission {3030, 3073} Caterpillar

Wheel Scraper

637K (S/N: WTT1-UP; WTY1-UP)

Wheel Tractor

637K (S/N: WTX1-UP)

Wheel Tractor Scraper

627H (S/N: LCT1-UP; DBW1-UP)

627K (S/N: WTC1-UP; WTN1-UP)

637K (S/N: WTS1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS3616
03	Standardized.Removed 631H. Added Effectivity.
02	Added serial number prefixes WTC, WTN, WTS and WTT. Added new machine models to Table 2.
01	Added serial number prefix WTR. Added new machine models to Table 2. Updated introduction. Inserted "Think Safety" graphic.

© 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 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:

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

• Knowledge Network

Table 2

Machine Model	Transmission Arrangement
627H	315-4727
627K	315-4727
637K	315-4727

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-9586	Support	2
	FT-2277	Swivel Support	2
	FT-2278	Swivel Head	2
	1U-9585	Block Gp	1
B	1U-5798	Drive Adapter Gp	1
	0S-1594	Bolt	4
	3B-4506	Lockwasher	4
C	1U-6698	Spindle Adapter	1
	2J-5245	Bolt (3/8-16X1.25 inch)	6
	3B-4506	Lockwasher	6
D	1U-5999	Spindle Gp	1
	3B-4506	Bolt (1/2-13X2.00 inch)	4
	3B-4508	Lockwasher	4
E	1U-6721	Adapter (Drive)	1
F	1U-9131	Drive AdapterKey (1)	1
G	1U-9359	Drive Adapter(2)	1
H	1U-9722	Load Binder as (Ratchet type)	3
	1P-7409	Bolts	2
	138-7575	Link Brackets	2
	0S-1587	Bolt	2
	5P-8245	Lockwasher	2
AA	4M-8815	Valve Cover(3)	1
	5B-4274	Forcing Bolt (3/8-16X3 inch)(3)	1
J	1U-9879	Fitting	1
	5L-6669	Reducer Bushing	1
	8B-9580	Pipe Reducer (2 1/4)	1
	139-8383	Pipe Reducer (1 1/4)	1
	1U-9856	Flange	1
K	1U-9870	Four Bolt Flange	1
	8C-9024	Quick Coupler	1
L	120-6843	Ball Valve	1
	8C-9024	Fitting As (Plain)	1
	8C-9025	Quick Coupler	1
	3B-7749	Fitting	1
M	1U-9852	Flange	1
	8C-9024	Flange	1
	0S-1594	Bolt	2
	3B-4506	Lockwasher	2
N	1U-9852	Flange	1
	0S-1594	Bolt (3/8-16X1 inch)	2
	3B-4506	Lockwasher	2
	002-5743	45 Degree Elbow	1
	124-1922	Male Swivel	1
	122-6873	Hose	1
BB	1U-9852	Flange	1
	8C-9024	Flange	1
	0S-1594	Bolt	2
	3B-4506	Lockwasher	2
P	109-5605	Adapter	1
	5B-7666	90 Degree 1 1/2 inch	1
	8C-9024	Male Quick Disconnect	1
	8B-5774	Pipe Reducer	1
	0S-1571	Bolt (3/8-16X1 1 3/4 inch)	4
	5M-2894	Washer	4
R	6V-4142	Fitting	1
	3B-7282	Pipe Nipple	1
S	6V-4142	Fitting	1
	3B-6552	Elbow	1
	3B-7283	Pipe Nipple	1
T	8T-3613	Nipple	1
U	9S-9145	Plastic Plate	1
V	6V-3965	Fitting	1
W	6V-3965	Fitting	1
X	6V-3965	Fitting	1
	9B-3523	Adapter	1
Y	6V-3965	Fitting	1
Z	277-2362	Transmission Analyzer Tool Gp	1
	9U-7498	Extension Cable	1
	9U-7495	Adapter Cable as (Power Shift Transmission)	1

(1)	This drive adapter is used with the small drive shaft.
(2)	This drive adapter is used with the large drive shaft.
(3)	Refer to Illustration 1 for further information.

Illustration 3	g01074498

FT Drawings

Illustration 4	g03831077
FT-2277

Illustration 5	g03836221
FT-2278 (A) 0L-1169 Bolt (B) 2S-7593 Hard Washer (C) 1D-4720 Nut

Installation Procedure

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Illustration 6	g06040782

1. Install Tooling (A) on the rails of the test bench.
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   Illustration 7	g01037969

2. Install Tooling (B) on the torque converter.
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   Illustration 8	g01037970

3. Install Tooling (C) to the transmission case.
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   Illustration 9	g01037971

4. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1610 kg (3550 lb).
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   Illustration 10	g06040789

   Note: Refer to Special Instruction, SEHS8763, "Assembly and Operation of 1U-5999 Spindle Group Used for Testing Transmissions on Hydraulic Test Bench" for additional information.

5. Install Tooling (D) on Tooling (C).
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   Illustration 11	g02561118

6. Loosen bolt (1).
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   Illustration 12	g06040896

7. Use bolt (2) to adjust Tooling (D) inward.
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   Illustration 13	g01037975

8. Tighten the collet on Tooling (D) to connect Tooling (D) to Tooling (B).

9. Tighten bolt (1) only after you adjust Tooling (D).
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   Illustration 14	g02561157

10. Install Tooling (E) to the input shaft of Tooling (D).
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    Illustration 15	g01037977

11. Install Tooling (F) to the input shaft of Tooling (E).

    Note: Tooling (F) will adapt to the small drive shaft. If you are using the large drive shaft, install Tooling (G) on Tooling (F).

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    Illustration 16	g01037978

12. Align the transmission with the input drive shaft.

13. Connect the input drive shaft to Tooling (F).
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    Illustration 17	g01037979

14. Install the drive shaft guard.
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    Illustration 18	g03802221

15. Tighten all four castle nuts and jack bolts.
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    Illustration 19	g01037980

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    Illustration 20	g01037981

16. Install Tooling (H) to the output end of the transmission.
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    Illustration 21	g01037982

17. Install Tooling (H) to the input end of the transmission.
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    Illustration 22	g01037984

18. Loosen cover (3).
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    Illustration 23	g03412039

19. Install Tooling (AA).
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    Illustration 24	g01037986

20. Install Tooling (J).
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    Illustration 25	g01037987

21. Install Tooling (K).
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    Illustration 26	g01037988

22. Connect Tooling (L) to Tooling (K).
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    Illustration 27	g01037989

23. Install Tooling (M).
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    Illustration 28	g01037991

24. Install Tooling (N).
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    Illustration 29	g03412041

25. Install Tooling (BB).
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    Illustration 30	g01037993

26. Install Tooling (P).
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    Illustration 31	g02561162

27. Remove cover (5).
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    Illustration 32	g01037998

28. Remove three plugs (6).
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    Illustration 33	g02568256

29. Install Tooling (R), (S), (T), (U).
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    Illustration 34	g02570717

30. Install Tooling (V).
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    Illustration 35	g02570860

31. Install Tooling (W).
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    Illustration 36	g01038005

32. Install Tooling (X).
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    Illustration 37	g01038006

33. Install Tooling (Y).
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    Illustration 38	g02570921

34. Connect hose assembly (7) from the pump supply to Tooling (J).
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    Illustration 39	g01038008
    Torque Converter Outlet

35. Connect hose assembly (8) from Tooling (L) to the No. 2 flow meter inlet.
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    Illustration 40	g01038009
    Inlet For The Transmission Lubrication Oil

36. Connect hose assembly (9) from the No. 2 flow meter outlet to Tooling (M).
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    Illustration 41	g03412045

37. Connect hose assembly (10) to Tooling (BB).
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    Illustration 42	g01038011
    Transmission Scavenge Oil

38. Connect hose assembly (10) from the pump supply to Tooling (P).
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    Illustration 43	g02570964

39. Connect lube line (12) from the test bench to Tooling (D). Maintain an oil pressure of 275 kPa (40 psi).
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    Illustration 44	g02571190
    (13) "P1" Pressure (14) "P2" Pressure (15) Converter Inlet Pressure

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

40. Connect pressure gauge (13) to Tooling (S).

41. Connect pressure gauge (14) to Tooling (R).

42. Connect pressure gauge (15) to Tooling (T).
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    Illustration 45	g02571216
    Pump Supply Pressure

43. Connect pressure gauge (16) to Tooling (V).
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    Illustration 46	g02571221
    Torque Converter Outlet Pressure

44. Connect pressure gauge (17) to Tooling (X).
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    Illustration 47	g02571229
    Lockup Clutch Pressure

45. Connect pressure gauge (18) to Tooling (W).
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    Illustration 48	g02571436
    Transmission Lubrication Gauge

46. Connect pressure gauge (19) to Tooling (Y).
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    Illustration 49	g02571656
    (20) Upshift Solenoid (21) Downshift Solenoid (22) Synchronization Solenoid

47. Connect Tooling (Z) to solenoid (20), solenoid (21), and solenoid (22).
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    Illustration 50	g02571477

48. Connect Tooling (Z) to harness connector (23).
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    Illustration 51	g01038023

49. Connect Tooling (Z) to a suitable location.
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    Illustration 52	g01457869
    Tooling (Z)

50. Connect Tooling (Z) to a power source. Refer to Tool Operating Manual, NEHS0644 for the correct operating instructions.

Test Procedure

TA3 Navigation

1. Select “Scrapers”.

2. Select “637E 4/8 spd”.

Harness Test (TA3 Only)

1. Make sure that the harness is properly connected.

2. Use Tooling (Z) to perform the solenoid test.

3. Record the values in Table 6.

   Note: Do not continue testing until Harness Test passes.

Start Checks

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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.

Note: Refer to Testing and Adjusting, KENR8878 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 the input flow to 57 ± 4 L (15 ± 1 US gal).
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   Illustration 53	g02720621

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 650 ± 30 rpm.

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

5. Verify 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
   N			X
   R		X		X
   F1		X			X
   F2	X				X
   F3		X	X
   F4	X		X

6. Stop the input rotation.

Relief Valve Check (Torque Converter Inlet)

1. With the transmission in the NEUTRAL position, adjust the input rotation to 650 ± 30 rpm.

2. Shift the transmission to FORWARD 1.

3. The torque converter outlet pressure must be 41 kPa (6 psi) Minimum.

4. Use Tooling (L) to momentarily block the flow at the torque converter outlet.

5. The "P3" torque converter inlet pressure must be 807 ± 55 kPa (117 ± 8 psi).

6. Open Tooling (L).

7. Record the value in Table 8.

8. Shift the transmission to the NEUTRAL position.

Lockup Clutch

1. With the transmission in the NEUTRAL position, adjust the input rotation to 650 ± 30 rpm.

2. Shift the transmission to FORWARD 1.

3. The pressure at the lockup clutch tooling "W" must match the pressure at the "P2".

4. Shift the transmission to the NEUTRAL position.

Low Idle Pressure Checks

1. With the transmission in the NEUTRAL position, adjust the input rotation to 650 ± 30 rpm.

2. Record the input flow, the "P1" pressure, the "P2" pressure, and the priority valve pressure in Table 9.

3. Verify the test points with the values in Table 7.

4. Shift the transmission through each FORWARD and REVERSE speed range. Repeat Steps 2 and 3 for each position.

   Note: Always return to NEUTRAL when shifting between FORWARD and REVERSE.

5. Shift the transmission to the NEUTRAL position.

High Idle Pressure Checks

1. With the transmission in the NEUTRAL position, adjust the input rotation to 2200 ± 5 rpm.

2. Record the input flow, the "P1" pressure, the "P2" pressure, and the lubrication pressure in Table 10.

3. Verify the test points with the values in Table 7.

4. Shift the transmission through each FORWARD and REVERSE speed range. Repeat Steps 2 and 3 for each position.

   Note: Always return to NEUTRAL when shifting between FORWARD and REVERSE.

5. Shift the transmission to the NEUTRAL position.

6. Stop the input rotation.

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.:_______

Solenoid Test

Table 6

Solenoid Test	Solenoid 1	Solenoid 2	Solenoid 3
	_______ ohms	_______ ohms	_______ ohms

Specifications

Table 7

General Specifications
Description	High Idle	Low Idle
Input Speed	2200 ± 5 rpm	650 ± 30 rpm
Input Flow	103 L/min (27 US gpm) Minimum	19 L/min (5 US gpm)
Pressures
P1(1)		621 ± 97 kPa (90 ± 14 psi)
P1	2724 ± 103 kPa (395 ± 15 psi)	2377 kPa (345 psi)
P2	P1 - 345 ± 55 kPa (P1 - 50 ± 8 psi)	P1 - 345 ± 55 kPa (P1 - 50 ± 8 psi)
Converter Inlet (2)		807 ± 55 kPa (117 ± 8 psi)
Converter Outlet	558 + 103 - 145 kPa (81 + 15 - 21 psi)	41 kPa (6psi)
Priority Valve (3)		1310 ± 207 kPa (190 ± 30 psi)
Lubrication	90 ± 34 kPa (13 ± 5 psi)	28 kPa (4 psi) Minimum

(1)	Pressure reading with transmission in NEUTRAL
(2)	Pressure with flow to lube restricted
(3)	Pressure at pump tap (filter) with transmission in NEUTRAL

Relief Valve Check (Torque Converter Inlet)

Table 8

Relief Valve Check (Torque Converter Inlet)

Input Speed (650 ± 30 rpm)

_______kPa _______(psi)

Low Idle Pressure Checks

Table 9

Low Idle Pressure Checks				Input Speed (650 ± 30 rpm)
Gear Range	N	R	F1	F2	F3	F4
Input Flow
"P1" Pressure
"P2" Pressure
"Priority Valve" Pressure

High Idle Pressure Checks

Table 10

High Idle Pressure Checks			Input Speed (2200 ± 5 rpm)
Gear Range	N	R	F1	F2	F3	F4
Input Flow
"P1" Pressure
"P2" Pressure
Lubrication Pressure

Contamination Control

Table 11

ISO Particle Count

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

________/________Particle Count

Table 12

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______________________________________ Supervisor