This instruction is intended to be used for flushing the hydraulic system of 613 Tractor-Scrapers which have experienced a hydraulic component failure. A hydraulic failure can be detected by slower than normal operation of one or more hydraulic circuits, or drifting of the hydraulic cylinders.
Three 3H5522 Plates are needed to flush the contaminated hydraulic system on 613 Tractors - 71M1-71M943, and 71M1071-up.
The following parts are needed to flush the contaminated hydraulic system on 613 Tractors - 71M944 through 71M1070.
- 4 - 3B4506 Lockwasher4 - 5B2638 Bolt1 - 5F3144 Seal3 - 3H5522 Plate1 - 3J5553 Gasket1 - 1J3619 Plate1 - 5M596 Cover1 - 8S8365 Hose Assembly (or Fabricated Hose shown below)1 - Fabricated Block (shown below)1 - Fabricated Gasket (to fit block)1 - Fabricated Plate (F) (shown on Page 2)
The 8S8365 Hose Assembly (A) can be assembled using a 72" (1828) or longer hose with the fittings shown above.
Fabricate block (B) as dimensioned above.
Fabricate plate (F) as dimensioned above.
Machine Preparation (613)/71M944 - 71M1070
(1) Drain, then remove the hydraulic oil tank.
(2) Remove the bottom cover and clean the tank and all of its components. Be sure that all metal particles are removed from the filter housing and the two oil discharge tubes in the tank. Install the cleaned tank.
(3) Clean the filter cover and the filter bypass valve; install a new 4J6064 Filter Element and the filter cover.
(4) Remove the elevator hydraulic pump (1). Disassemble the pump and inspect all parts for damage. Replace any severely damaged parts. Light scratches on the pump cam ring and end plates will not affect the pump performance. Reassemble the pump. Remove the pump suction line, clean and reinstall the line only. Place the pump on the lines near its mounting location but do not install the pump at this time.
- A. Remove the drive shaft guard mounting bolts and slide the guard toward the rear of the machine.
- B. Disconnect the pump suction line and all other lines from the pump.
- C. Loosen the four end cover bolts and remove the top two bolts.
- D. Remove the two pump mounting bolts and rotate the pump to remove the remaining two end cover bolts.
- E. Remove the cover, then remove the pump, disassemble and replace any damaged parts. Clean, lubricate, assemble and reinstall the pump and pump lines.
- B. Disconnect the pump suction line and all other lines from the pump.
(5) Remove the steering and scraper hydraulic pump (2) following the procedure outlined below.
(6) Remove the steering cylinders, bowl lift cylinders, ejector cylinder and the floor cylinder. Disassemble, inspect and replace any damaged piston seals or badly scored pistons. Hone any lightly scored cylinders. Replace the cylinder if scoring cannot be removed by honing to a .0035" ± .0005" (0,088 ±0,013) increase in cylinder diameter.
| NOTICE |
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If the piston is removed from the cylinder rod, take care during reassembly of the piston on the rod. Earlier machines used aluminum "screw-on" pistons. Tighten these aluminum pistons to a torque of 150 to 200 lb. ft. (20,7 to 27,6 mkg). Tighten the lock nut to a torque of 1000 ± 120 lb. ft. (138,3 ± 16,6 mkg). All ejector cylinders are of this type. On later models, tighten the piston nut of the cylinders below to the applicable torque. |
- 7J5528 - Floor Cylinder - 1600 ± 160 lb. ft. (221,2 ± 22,1 mkg)7J6054 - Steering Cylinder - 1200 ± 120 lb. ft. (165,9 ± 16,6 mkg)7J6058 - Bowl Lift Cylinder - 1200 ± 120 lb. ft. (165,9 ± 16,6 mkg)
(7) Remove the cartridge from the elevator motor. Inspect and replace any damaged parts. Clean all reused parts thoroughly, then reassemble the cartridge. Reinstall the cartridge and fill the motor completely with clean oil before reconnecting the lines.
(8) Remove ejector and floor hose assemblies (3), (4), (5), (6) and tube assemblies (7) and (8). Flush these lines thoroughly with clean diesel fuel. Reinstall the cleaned lines.
(9) Install the 5M596 Cover and the 5F3144 Seal at the elevator pump mounting location on the torque converter drive housing. Install the 1J3619 Plate on the pump end of suction line (9).
(10) Remove tube (10) from tank, 7J6573 Hose and the steering system return line.
(11) Inspect ports (D) and (E) in tube (10). Shaded portions of Section C-C illustrate areas where contaminates may be lodged. Remove all metal shavings and metal contaminates using a pick or sharp tool. After all contaminates have been removed, clear the tube of any loose or trapped particles using high pressure air.
(12) Reinstall tube (10) using fabricated plate (F) and the 3J5553 Gasket between tube (10) and the oil tank flange.
(13) Install fabricated block (B) and the appropriate gaskets between the upper flange of tube (10) and hose assembly (12).
(14) Disconnect the 7J5758 Hose Assembly (11) from the 7J6610 Block on the hydraulic oil tank and connect the 90° stem end of the 8S8365 Hose Assembly or fabricated hose (A) to the 7J6610 Block. Connect the straight stem end of hose (A) to the open port on block (B).
Machine Preparation 613 71M1 - 71M943, 71M1071 - Up
(1) Drain, then remove the former hydraulic tank. (Machines with serial numbers 71M1071 and up are already equipped with the new type tank and the tanks on these machines need not be removed.) Install the new 8J5248 Reservoir Group on machines 71M1 - 71M943 as shown in Special Instruction Form GMG02104.
(2) Remove the elevator hydraulic pump (1). Disassemble the pump and inspect all parts for damage. Replace any severely damaged parts. Light scratches on the pump cam ring and end plates will not affect the pump performance. Reassemble the pump. Remove the pump suction line, clean and reinstall the line and the pump.
- A. Remove the drive shaft guard mounting bolts and slide the guard toward the rear of the machine.
- B. Disconnect the pump suction line and all other lines from the pump.
- C. Loosen the four end cover bolts and remove the top two bolts.
- D. Remove the two pump mounting bolts and rotate the pump to remove the remaining two end cover bolts.
- E. Remove the cover, then remove the pump, disassemble and replace any damaged parts. Clean, lubricate, assemble and reinstall the pump and pump lines.
- B. Disconnect the pump suction line and all other lines from the pump.
(3) Remove the steering and scraper hydraulic pump (2) following the procedure outlined below.
(4) Remove the steering cylinders, bowl lift cylinders, ejector cylinder and the floor cylinder. Disassemble, inspect and replace any damaged piston seals or badly scored pistons. Hone any lightly scored cylinders. Replace the cylinder if scoring cannot be removed by honing to a .0035" ± .0005" (0,088 ± 0,013) increase in cylinder diameter.
| NOTICE |
|---|
If the piston is removed from the cylinder rod, take care during reassembly of the piston on the rod. Earlier machines used aluminum "screw-on" pistons. Tighten these aluminum pistons to a torque of 150 to 200 lb. ft. (20,7 to 27,6 mkg). Tighten the lock nut to a torque of 1000 ± 120 lb. ft. (138,3 ± 16,6 mkg). All ejector cylinders are of this type. On later models, tighten the piston nut of the cylinders below to the applicable torque. |
- 7J5528 - Floor Cylinder - 1600 ± 160 lb. ft. (221,2 ± 22,1 mkg)7J6054 - Steering Cylinder - 1200 ± 120 lb. ft. (165,9 ± 16,6 mkg)7J6058 - Bowl Lift Cylinder - 1200 ± 120 lb. ft. (165,9 ± 16,6 mkg)
(5) Remove the cartridge from the elevator motor. Inspect and replace any damaged parts. Clean all reused parts thoroughly, then reassemble the cartridge. Reinstall the cartridge and fill the motor completely with clean oil before reconnecting the lines.
(6) Remove ejector and floor hose assemblies (3), (4), (5), (6) and tube assemblies (7) and (8). Flush these lines thoroughly with clean diesel fuel. Reinstall the cleaned lines.
Circuit Preparation All 613 Tractors
(1) Connect left steering cylinder hose (13) to hose (14) and connect right steering cylinder hose (15) to hose (16), using 3H5522 Plates between the hoses.
NOTE: Use the 3H5522 Plates normally located at the cylinder rod ends.
(2) Connect bowl lift cylinder hose (17) to hose (18) and connect hose (19) to hose (20) using 3H5522 Plates between the hoses.
NOTE: On Tractors 71M1 - 71M354 use 7J8835 Plates between the hoses. The 7J8835 Plates are normally located at the cylinder rod ends.
(3) Connect the ends of ejector hoses (21) and (22) using a 3H5522 Plate.
(4) Fill the hydraulic oil tank, to the top of the filler pipe, with clean oil.
Circuit Decontamination 613 Tractors 71M1 - 71M943, 71M1071-Up
(1) Start the tractor engine and run it at low idle. Turn the steering wheel in one direction, then the other, pausing momentarily between each direction. Actuate the bowl control lever and the ejector control lever in both directions. Check for any oil leaks and correct if necessary. Refill the hydraulic oil tank to the top of the sight gauge.
(2) Run the engine at 2000 RPM and cycle the steering circuit, the bowl lift circuit and the ejector circuit for five minutes each, in each direction. Total cycle time should be approximately 30 minutes. Stop the engine when the cycling has been completed.
(3) Reinstall the six hydraulic cylinders and connect all of the lines to their respective cylinder locations.
(4) Start the engine and run it at low idle. Move the steering wheel and all control levers until all of the cylinders have been filled with oil.
| NOTICE |
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Be sure to check the oil level frequently during this filling period. Maintain the oil level to the top of the sight gauge. |
(5) Run the engine at 2000 RPM. Operate the elevator for five minutes in each direction.
(6) Stop the engine and replace the hydraulic filter element.
(7) With the new filter element in the circuit, operate all hydraulic circuits to insure proper performance; check for any oil leaks.
Circuit Decontamination 613 Tractors 71M944 - 71M1070
(1) Start the tractor engine and run it at low idle. Turn the steering wheel in one direction, then the other, pausing momentarily between each direction. Actuate the bowl control lever and the ejector control lever in both directions. Check for any oil leaks and correct if necessary. Refill the hydraulic oil tank to the top of the sight gauge.
(2) Run the engine at 2000 RPM and cycle the steering circuit, the bowl lift circuit and the ejector circuit for five minutes each, in each direction. Total cycle time should be approximately 30 minutes. Stop the engine when the cycling is completed.
(3) Drain the hydraulic oil into a clean container: (The hydraulic oil can be reused if drained into a completely clean container.)
(4) Install the elevator hydraulic pump and connect suction line (1).
(5) Remove fabricated block (B) and hose (A). Reconnect the scraper cylinder return line (12) to tube (2), and connect hose (11) to the 7J6610 Block on the tank. Remove the fabricated plate (F) and the gasket from between the tank port and tube (2). Fill the hydraulic oil tank to the top of the filler pipe.
(6) Reinstall the six hydraulic cylinders and connect all of the lines to their respective cylinder locations.
(7) Start the engine and run it at low idle. Move the steering wheel and all control levers until all of the cylinders have been filled with oil.
| NOTICE |
|---|
Be sure to check the oil level frequently during this filling period. Maintain the oil level to the top of the sight gauge. |
(8) Run the engine at 2000 RPM. Operate the elevator for five minutes in each direction.
(9) Stop the engine and replace the hydraulic filter element.
(10) With the new filter element in the circuit, operate all hydraulic circuits to insure proper performance; check for any oil leaks.