Testeo Transmision

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine(S...
Page 1 of 31
Cerrar SIS
Pantalla anterior
Producto: TRUCK
Modelo: 777F TRUCK JRP
Configuracin: 777F Off-Highway Truck JRP00001-UP (MACHINE)
POWERED BY C32 Engine
Procedimientos de prueba de banco

Bench Test Procedure For A 777F Off-Highway Truck Transmission{3030, 3073}
Nmero de medio -REHS3436-00
Fecha de publicacin -08/03/2007
Fecha de actualizacin -08/03/2007

i02630853
Bench Test Procedure For A 777F Off-Highway Truck

Transmission{3030, 3073}
SMCS - 3030; 3073
Off-Highway Truck/Tractor:
777F (S/N: JRP1-UP)
Introduction
This special instruction contains the necessary information that is required to bench test specific
transmission arrangements. Refer to Table 1 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 in order 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.
Table 1
Machine Model
Transmission Arrangement
777F
246-2647
Collecting the Test Data

Since conditions vary for each test bench, it is important 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 often used in order 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.
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 07/08/2009
777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine(S... Page 2 of 31
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.
Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.
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 2 were used in
order to develop this test procedure.
Table 2
Required Tools
Tool
Part Number
1U-9584
Rail As
1U-5810
Plate As (Spindle Adapter)
1A-8063
Bolt (3/4-10X2.5 inch)
5P-8248
Hard Washer
2J-3506
Full Nut
9F-2535
90o Pipe Street Elbow
140-7299
Pipe Nipple
Part Description
Qty
1U-9586
Swivel Head Support Gp
4C-9908
Drive Adapter
5B-0841
Bolt (5/8-18X1.75 inch)
3B-4510
Lockwasher
1U-9131
Drive Adapter (Key) (1)
1U-9359
Drive Adapter (2)
138-7574
Link Bracket
0S-1587
Bolt (1/2-13X1.75 inch)
5P-8245
Hard Washer
1U-9722
Load Binder As (Ratchet Type)
1U-8653
Adapter (Splined)
1U-5999
Spindle Gp
8B-7997
Bolt (1/2-13X2.0 inch)
3B-4506
Lockwasher
Fitting
9U-7446
Adapter
1P-4579
Half Flange
8C-9024
Fitting As (Plain)
6V-3965
Fitting As (Quick Disconnect)
3J-1907
O-Ring Seal
0T-0772
Bolt (7/16-14x1.5 inch)
5P-8244
Hard Washer
Fitting
9U-7446
Adapter
1P-4579
Half Flange
8C-9024
Fitting As (Plain)
6V-3965
Fitting As (Quick Disconnect)
3J-1907
O-Ring Seal
0T-0772
Bolt (7/16-14x1.5 inch)
5P-8244
Hard Washer
Manifold
1U-8301
1U-8301
305-7492
1F-6296
Bolt (5/16-18X5.0 inch)
061-8246
Connector
1S-7462
O-Ring Seal
004-7270
Nipple (Pipe)
3B-6554
Elbow
Test Cover
Bolt (3/8-16X.75 inch)
26
Fitting
7X-7646
Nipple (Plain)
6B-9081
Bushing (Reducing)
Electronic Control Gp
Adapter Cable As (Test)
305-7491
P
0S-0509
6L-5295
Q
277-2363
R
305-7401
(1)
This drive adapter is used with the small drive shaft.
(2)
This drive adapter is used with the large drive shaft.
Installation Procedure
Illustration 1
g01319479
1. Install Tooling (A) on the rails of the test bench, as shown.
Illustration 2
g01319482
2. Remove threaded plug (1) .
Illustration 3
g01319484
3. Install Tooling (B) .
Illustration 4
g01319487
4. Install Tooling (C) to Tooling (B) .
Illustration 5
g01319488
5. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1587.6
kg (3500 lb).
Illustration 6
g01319531
6. Install Tooling (D) to the input yoke.
Illustration 7
g01319532
7. Install Tooling (E) on Tooling (D) .

Note: Tooling (E) will adapt to the small drive shaft. If you are using the large drive shaft it will
be necessary to install Tooling (F) on Tooling (D) .
Illustration 8
g01319533
8. Align the transmission with the input drive shaft.

9. Connect the input drive shaft to Tooling (E) .
Illustration 9
g01319543
10. Install Tooling (G) to the input end of the transmission.
Illustration 10
g01319545
Illustration 11
g01319550
11. Install Tooling (H), as shown.
777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine... Page 10 of 31
Illustration 12
g01319579
12. Install Tooling (J) .
Illustration 13
g01319581
13. Use a hoist to install Tooling (K). The weight of Tooling (K) is 121 kg (267 lb).
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.
Illustration 14
g01319583
14. Loosen bolt (2) .
Illustration 15
g01319585
15. Use bolt (3) to adjust Tooling (K) inward until Tooling (K) contacts the carrier. Tooling (K) will
slide into Tooling (J) .
Illustration 16
g01319586
16. Tighten the collet on Tooling (K) in order to connect Tooling (K) to Tooling (J) .
17. Adjust Tooling (K) in order to provide a 3.0 - 4.0 mm (0.12 - 0.16 inch) gap spacing between
Tooling (K) and the carrier.
Note: The measurement may be taken through the access hole in Tooling (B) .
18. Tighten bolt (2) .
Illustration 17
g01319665
19. Remove cover (4) .
Illustration 18
g01319611
20. Install Tooling (L) .
Illustration 19
g01319612
21. Install Tooling (M) .
Illustration 20
g01319614
22. Remove cover (5) .
Illustration 21
g01319615
23. Remove oil lines (6) from valve (7) .

24. Remove valve (7) .
Illustration 22
g01319619
25. Install Tooling (N) .
Illustration 23
g01319621
26. Install valve (7) to Tooling (N) .

27. Install oil lines (6) to valve (7) .
Illustration 24
g01319698
28. Install Tooling (P) .
Illustration 25
g01319699
29. Install Tooling (Q) .
Illustration 26
(8) Transmission Supply Oil
g01319715
30. Connect Hose Assembly (8) from the pressurized flow meter on the test bench to Tooling (L) .
Illustration 27
g01319716
31. Connect Hose Assembly (9) from Tooling (Q) to the inlet of the "Number 2" flow meter.
Illustration 28
g01319718
32. Connect Hose Assembly (10) from the outlet of the "Number 2" flow meter to Tooling (M).
Note: The "Number 2" flow meter will measure the lube flow.
Illustration 29
g01319719
33. Connect Hose Assembly (11) from the auxiliary oil supply at the test bench to Tooling (K).
Maintain an oil pressure of 275 kPa (40 psi).
Illustration 30
(12) System Pressure
g01319720
34. Connect a pressure gauge to test port (12) .
Illustration 31
(13) Input Transfer Gear Lube Pressure
g01319722
Illustration 32
(14) Lubrication Pressure
g01319723
Illustration 33
g01319724
(15) No. 6 Clutch Pressure


37. Connect a pressure gauge to each of the clutch pressure taps (15), (16), (17), (18), (19), (20), and
(21) .
Illustration 34
Tooling (R)
g01332830
Illustration 35
g01319727
38. Install Tooling (R).
Note: Refer to Tool Operating Manual, NEHS0966 for the correct operating instructions.
Test Procedure
Solenoid Test
1. Make sure that the harness is properly connected.
2. Use Tooling (R) to perform the solenoid test.
3. Record the values in Table 7.
Preliminary Checks
Note: Refer to Testing and Adjusting, RENR8303, "777F Off-Highway Truck 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.
2. Adjust the input flow to 170.3 3.8 L/min (45.0 1.0 US gpm).
Illustration 36
g01319754
3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise
direction. Adjust the input rotation to 700 30 rpm.
Note: The input shaft will be rotated in a counterclockwise direction for the duration of this test.
The direction is determined as you face the drive motor of the test bench.
4. Shift the transmission through all directions and through all speed ranges in order to eliminate air
from the transmission controls.
5. Check for lockup or excessive drag in all speed ranges.

6. Stop the input rotation.
Lube Check
2. Adjust the input rotation to 1300 10 rpm.
3. Shift the transmission to the REVERSE position.
4. Record the lubrication pressure in Table 8.
5. Record the lube flow in Table 8.
6. The lubrication pressure must be 620.5 34.5 kPa (90.0 5.0 psi).
7. The lube flow must be 170.3 3.8 L/min (45.0 1.0 US gpm).
8. Shift the transmission through positions NEUTRAL, FORWARD 1, FORWARD 2, FORWARD
3, FORWARD 4, FORWARD 5, FORWARD 6, and FORWARD 7. Repeat Steps 4 through 5 for
each gear range.
10. Shift the transmission to the NEUTRAL position.
Pressure Check (Low Idle)

3. Shift the transmission through ranges REVERSE, NEUTRAL, FORWARD 1, FORWARD 2,
FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, and FORWARD 7.
4. Record the clutch pressure for each range in Table 9.
5. Verify that the clutch pressures match the values in Table 3.
Table 3
Clutch
Speed Range
No.
No.
No.
No.
No.
(1)
(1)
(1)
(1)
(1)
(1)
Engaged
Clutches
1 and 7
REVERSE
No.
2
No.
7 (1)
Pressure
2765
kPa
2820
kPa
(401
psi)
NEUTRAL
FORWARD
1
2 and 6
FORWARD
2
1 and 6
FORWARD
3
3 and 6
FORWARD
4
1 and 5
FORWARD
5
3 and 5
FORWARD
6
1 and 4
FORWARD
7
3 and 4
(1)
(409
psi)
2765
kPa
(401
psi)
2103
kPa
(305
psi)
2792
kPa
(405
psi)
2765
kPa
(401
psi)
2806
kPa
(407
psi)
2289
kPa
(332
psi)
2792
kPa
(405
psi)
2758
kPa
(400
psi)
2096
kPa
(304
psi)
2289
kPa
(332
psi)
2737
kPa
(397
psi)
2096
kPa
(304
psi)
2124
kPa
(308
psi)
2282
kPa
(331
psi)
2137
kPa
(310
psi)
The tolerance is 68.9 kPa ( 10 psi).
Pressure Check (High Idle)


3. Shift the transmission through ranges REVERSE, NEUTRAL, FORWARD 1, FORWARD 2,
FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, and FORWARD 7.
4. Record the clutch pressure for each range in Table 10.
5. Verify that the clutch pressures match the values in Table 4.
Table 4
No.
1 (1)
Clutch
Speed Range
REVERSE
NEUTRAL
FORWARD
1
No.
2 (1)
No.
3 (1)
Engaged
Clutches
1 and 7
1 and 6
FORWARD
3
3 and 6
FORWARD
4
1 and 5
No.
5 (1)
No.
6 (1)
No.
7 (1)
Pressure
2813
kPa
(408
psi)
2910
kPa
(422
psi)
2834
kPa
(411
psi)
2144
kPa
(311
psi)
2 and 6
FORWARD
2
No.
4 (1)
2889
kPa
(419
psi)
2827
kPa
(410
psi)
2916
kPa
(423
psi)
2324
kPa
(337
psi)
2827
kPa
(410
psi)
2882
kPa
(418
psi)
2124
kPa
(308
psi)
FORWARD
5
3 and 5
FORWARD
6
1 and 4
FORWARD
7
3 and 4
(1)
2324
kPa
(337
psi)
2813
kPa
(408
psi)
2124
kPa
(308
psi)
2165
kPa
(314
psi)
2317
kPa
(336
psi)
2172
kPa
(315
psi)
The tolerance is 68.9 kPa ( 10 psi).
Clutch Leakage Check

1. Adjust the input flow to 170.3 3.8 L/min (45.0 1.0 US gpm). Maintain this flow for the
duration of this check.
2. Shift the transmission to the NEUTRAL position.
4. Record the supply pressure in Table 11. The correct supply pressure is 2964.8 34.5 kPa (430.0
5.0 psi).
5. Record the input flow in Table 11.
6. Record the cooler flow in Table 11.
7. The leakage is obtained by subtracting the cooler flow from the input flow.
8. Record the calculation in Table 11.
10. Shift the transmission through positions FORWARD 1, FORWARD 2, FORWARD 3,
FORWARD 4, FORWARD 5, FORWARD 6, FORWARD 7, and REVERSE. Repeat Steps 2
through 9 for each gear range. Adjust the input rotation to 800 30 rpm for all shifts.
11. Verify that the clutch leakages match the values in Table 5.
Table 5
Clutch
Subtract
2-1
Minimum Value
Maximum Value
-0.8 L/min (- 0.2 US gpm)
1.7 L/min (0.5 US gpm)
2-3
1
4-5
6-7
1-2
-5.6 L/min (-1.5 US gpm)
-1.6 L/min (-0.4 US gpm)
-5.4 L/min (-1.4 US gpm)
-1.7 L/min (-0.4 US gpm)
-6.2 L/min (-1.6 US gpm)
-2.7 L/min (-0.7 US gpm)
-1.7 L/min (-0.5 US gpm)
-6.0 L/min (-1.6 US gpm)
-2.2 L/min (-0.6 US gpm)
10.2 L/min (2.7 US gpm)
10.1 L/min (2.7 US gpm)
10.1 L/min (2.7 US gpm)
11.2 L/min (3.0 US gpm)
11.0 L/min (2.9 US gpm)
-1.5 L/min (-0.4 US gpm)
-1.7 L/min (-0.4 US gpm)
-10.1 L/min (-2.7 US gpm)
-5.4 L/min (-1.4 US gpm)
-1.6 L/min (-0.4 US gpm)
-11.0 L/min (-2.9 US gpm)
-6.0 L/min (-1.6 US gpm)
-1.7 L/min (-0.5 US gpm)
2
1-3
3-1
3-2
3
5-4
7-6
6-R
6-2
4
6-4
7-3
7-5
4-R
4-2
4-6
5-3
5-7
2-R
2-4
2-6
-1.6 L/min (-0.4 US gpm)
-10.1 L/min (-2.7 US gpm)
-5.0 L/min (-1.3 US gpm)
-1.2 L/min (-0.3 US gpm)
-11.2 L/min (-3.0 US gpm)
-5.7 L/min (-1.5 US gpm)
-1.6 L/min (-0.4 US gpm)
-1.1 L/min (-0.3 US gpm)
-10.2 L/min (-2.7 US gpm)
-5.1 L/min (-1.3 US gpm)
6
3-5
3-7
R-2
7
R-4
R-6
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 12.
3. Remove the transmission from the test bench if the test bench oil supply is within specifications.
Transmission Bench Test Data Sheet

Table 6
Test Date:
CATERPILLAR
Transmission Bench Test Data Sheet

Model:
Work Order:
Serial No.:
Solenoid Test
Table 7
Solenoid
Test
Solenoid
1
ohms
Solenoid
2
Solenoid
3
Solenoid
4
Solenoid
5
Solenoid
6
Solenoid
7
ohms
ohms
ohms
ohms
ohms
ohms
Lube Check
Table 8
Lube Check
Gear Range
Input Speed (1300 10 rpm)

Lubrication Pressure
Lube Flow
REVERSE
kPa (psi)
L/min (US gpm)
kPa (psi)
L/min (US gpm)
kPa (psi)
L/min (US gpm)
kPa (psi)
L/min (US gpm)
kPa (psi)
L/min (US gpm)
kPa (psi)
L/min (US gpm)
kPa (psi)
L/min (US gpm)
kPa (psi)
L/min (US gpm)
kPa (psi)
L/min (US gpm)
NEUTRAL
FORWARD 1
FORWARD 2
FORWARD 3
FORWARD 4
FORWARD 5
FORWARD 6
FORWARD 7

Table 9
Gear Range
Active Clutches
REVERSE
NEUTRAL
FORWARD 1

1
FORWARD 2
FORWARD 3
FORWARD 4
FORWARD 5
FORWARD 6
FORWARD 7

Table 10
Gear Range
Active Clutches
REVERSE
NEUTRAL
FORWARD 1
FORWARD 2
FORWARD 3
FORWARD 4
FORWARD 5
FORWARD 6
FORWARD 7

1
Table 11
Clutch Leakage
Check
Gear Range

Input Flow
170.3 3.8 L/min (45.0 1.0 US gpm)
1F
2F
3F
4F
5F
6F
7F
Supply
Pressure
______ ______ ______ ______ ______ ______ ______ ______ ______
Input Flow
______ ______ ______ ______ ______ ______ ______ ______ ______
Cooler Flow
Leakage
______ ______ ______ ______ ______ ______ ______ ______ ______
______ ______ ______ ______ ______ ______ ______ ______ ______
Average of
Arrangement ______ ______ ______ ______ ______ ______ ______ ______ ______
Table 12
Sample the test bench oil

supply.
________/________Particle Count
Table 13
______________________________________ ______________________________________
Supervisor
Technician
Copyright 1993 - 2009 Caterpillar Inc.

Todos los derechos reservados.
Red privada para licenciados del SIS.
Fri Aug 7 23:26:19 UTC-0400 2009

Testeo Transmision

Diunggah oleh

Informasi Dokumen

Judul Asli

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Testeo Transmision

Diunggah oleh

Hak Cipta:

Format Tersedia

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine(S...

Procedimientos de prueba de banco

Fecha de publicacin -08/03/2007

Fecha de actualizacin -08/03/2007

Bench Test Procedure For A 777F Off-Highway Truck

Collecting the Test Data

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine(S... Page 2 of 31

Hot oil and components can cause personal injury.

Plate As (Spindle Adapter)

Bolt (3/4-10X2.5 inch)

90o Pipe Street Elbow

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine(S... Page 3 of 31

Swivel Head Support Gp

Bolt (5/8-18X1.75 inch)

Drive Adapter (Key) (1)

Drive Adapter (2)

Bolt (1/2-13X1.75 inch)

Load Binder As (Ratchet Type)

Bolt (1/2-13X2.0 inch)

Fitting As (Quick Disconnect)

Bolt (7/16-14x1.5 inch)

Fitting As (Quick Disconnect)

Bolt (7/16-14x1.5 inch)

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine(S... Page 4 of 31

Bolt (5/16-18X5.0 inch)

Bolt (3/8-16X.75 inch)

Adapter Cable As (Test)

This drive adapter is used with the small drive shaft.

This drive adapter is used with the large drive shaft.

1. Install Tooling (A) on the rails of the test bench, as shown.

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine(S... Page 5 of 31

2. Remove threaded plug (1) .

3. Install Tooling (B) .

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine(S... Page 6 of 31

4. Install Tooling (C) to Tooling (B) .

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine(S... Page 7 of 31

6. Install Tooling (D) to the input yoke.

7. Install Tooling (E) on Tooling (D) .

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine(S... Page 8 of 31

8. Align the transmission with the input drive shaft.

10. Install Tooling (G) to the input end of the transmission.

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine(S... Page 9 of 31

11. Install Tooling (H), as shown.

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine... Page 10 of 31

12. Install Tooling (J) .

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine... Page 11 of 31

14. Loosen bolt (2) .

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine... Page 12 of 31

19. Remove cover (4) .

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine... Page 13 of 31

20. Install Tooling (L) .

21. Install Tooling (M) .

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine... Page 14 of 31

22. Remove cover (5) .

23. Remove oil lines (6) from valve (7) .

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine... Page 15 of 31

25. Install Tooling (N) .

26. Install valve (7) to Tooling (N) .

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine... Page 16 of 31

28. Install Tooling (P) .

29. Install Tooling (Q) .

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine... Page 17 of 31

777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine... Page 18 of 31