Performance Test Caterpillar OHT 777D

Team TC Asset Tabang Project

Performance Test
Caterpillar OHT 777D

PT. Petrosea
2020

Once printed this document becomes uncontrolled. Refer to Petrosea Intranet for controlled copy.
Error! Reference source not found. Rev No. A 1 of 12
 Performance Test Caterpillar OHT 777D

Valve Lash Adjustment & Injector Timing Engine

No Activity Description Visual

1. Menentukan Tool yang diperlukan:
Top Cylinder Tools Needed Quantity
No. 1 9S-9082 Engine 1
Turning Tool

1. Buka cover (1) dan plug (3) dari

sisi kanan depan flywheel housing.
2. Pasang timing bolt (2) melalui (1) Cover (2) Timing Bolt (3)
lubang timing pada flywheel Plug
housing. Gunakan Engine Turning
Tool (4) serta ratchet wrench
ukuran drive 1/2 inch untuk
memutar flywheel dengan arah
putaran normal engine. Putar
flywheel hingga timing bolt masuk
kedalam lubang timing pada (2) Timing Bolt (4) Engine
flywheel. Turning Tool
3. Buka cover camshaft pada salah
satu cylinder paling paling
belakang kiri ataupun kanan.
4. Ketika timing bolt terpasang pada
flywheel, perhatikan camshaft
paling belakang pada salah satu
sisi engine kiri ataupun kanan.
Lepaskan timing pin dari baut Camshaft Timing
bracketnya dan masukkan ke (1) Timing hole (2) Timing Pin
timing hole pada camshaft. Jika camshaft
timing pin camshaft masuk
kedalam lubang pada camshaft
berarti cylinder No.1 dalam kondisi
Top 1 Kompresi. Jika Timing Pin
camshaft tidak masuk kedalam
lubang camshaft maka cylinder
No.1 dalam kondisi Top 1
Exhaust.

Standar Pemeriksaan Cylinder Setelah Diputar 360o

Cylinder Yang Diperiksa
Engine Posisi Top Center Piston Inlet Exhaust Injectors
No. 1 Valves Valves
3508B Compression 1-2-6-8 1-2-3-7 2-3-4-7
Exhaust 3-4-5-7 4-5-6-8 1-5-6-8

Once printed this document becomes uncontrolled. Refer to Petrosea Intranet for controlled copy.
Error! Reference source not found. Rev No. A 2 of 12
 Performance Test Caterpillar OHT 777D

2. Adjust Spesifikasi Valve Lash

Valve Lash Valve Spesifikasi
Inlet 0.50 mm (0.020 inch
Exhaust 1.00 mm (0.040 inch
1. Pasang tool yang telah dirakit
pada lubang baut cover cylinder
head belakang pada tiap-tiap 1) 147-2060 Wrench.
cylinder yang akan distel. 2) 147-2059 Torque Wrench
2. Pastikan pointer tool menyentuh 3) 148-7211 Bridge Nut
dengan baik rocker arm pada Socket
valve yang akan distel. 4) 145-5191 Gauge Support
3. Gerakkan rocker arm keatas dan 5) 147-2056 Dial Indicator
kebawah untuk meyakinkan dial 6) 147-5536 Indicator
pada gauge bergerak dan telah Contact Point
menunjukkan angka Nol saat 7) 147-2057 Indicator
belum ditekan. Contact Point
4. Gerakkan rocker arm pada valve 8) 147-2058 Indicator
yang akan distel dan perhatikan Extension
pembacaan pada dial dan
sesuaikan dengan spesifikasi yang
ada.
5. Jika ada salah satu valve yang
butuh penyetelan maka
longgarkan locknut pada rocker
arm dan stel nilai yang diinginkan
dengan memutar adjustment Tool Setelah Dirakit
screw.
6. Kencangkan kembali locknut jika
penyetelah telah dilakukan dan
torque locknut sebesar 70 ± 15
N·m (50 ± 11 lb ft) menggunakan
torque wrench.Periksa kembali
adjustment setelah di torque. Tool Terpasang

1) Lock Nut
2) Adjusment Screw
3) Rocker Arm
4) Valve Lash

Once printed this document becomes uncontrolled. Refer to Petrosea Intranet for controlled copy.
Error! Reference source not found. Rev No. A 3 of 12
 Performance Test Caterpillar OHT 777D

3. Adjust Injector Tool Yang dibutuhkan

Timing Tools Needed Quantity
9U-5132 Engine 1
Timing
Tool Group
6V-3075 Dial Indicator 1
8S-3675 Indicator 1
Contact Point
9U-5138 Setting 1
Gauge
9U-5137 Magnetic 1
Fixture
122-0451 Timing 1
Fixture
122-0449 Rod Sleeve 1 1) Tool Fuel Injector Timing
9U-6272 Nylon Screw 1 2) 9U-5137 Magnetic Fixture
3) 122-0451 Timing Fixture
1. Kalibrasi tool fuel injector timing Rod
pada setting gauge. 4) 9U-5138 Setting Gauge
2. Gunakan nilai 64.34 mm sebagai 5) 6V-3075 Dial Indicator
patokan pada setting gauge untuk
megkalibrasi tool fuel injector
timing.
3. Gauge harus menunjukkan angka
nol ketika dikalibrasi pada setting
gauge.
4. Letakkan tool pada injector yang
akan dikalibrasi.
5. Pastikan pointer tool telah duduk
dengan tepat pada tempat yang
tepat. Posisi Tool Fuel Injector
6. Perhatikan gauge untuk melihat Timing
penyimpangan yang terjadi pada 1) 9U-5137 Magnetic Fixture
injector. 2) 6V-3075 Dial Indicator
7. Jika terjadi penyimpangan pada 3) Injector follower
dial maka penyetelan harus 4) Shoulder
dilakukan.
8. Longgarkan locknut dan stel
adjusment screw untuk
mengembalikan dial keposisi nol.
9. Jika telah selesai melakukan
penyetelan kencangkan kembali
lock nut dan torque sebesar 120 ±
15 N·m (90 ± 11 lb ft).
Posisi Tool Injector Timing
10. Periksa kembali penyimpangan
pada dial setelah locknut
dikencangkan.

Spesifikasi ketinggian injector

adalah 64.34 ± 0.20 mm (2.533 ±
0.008 inch)
Once printed this document becomes uncontrolled. Refer to Petrosea Intranet for controlled copy.
Error! Reference source not found. Rev No. A 4 of 12
 Performance Test Caterpillar OHT 777D

1) Lock Nut
2) Adjusment Screw
3) Rocker Arm
4) Dimensi Ketinggian Injector

Once printed this document becomes uncontrolled. Refer to Petrosea Intranet for controlled copy.
Error! Reference source not found. Rev No. A 5 of 12
 Performance Test Caterpillar OHT 777D

Testing Adjusting Torque Converter & Brake System

No Activity Description Visual
1. Torque 1) Transmisi posisi Reverse
Converter 2) Engine Stall Speed
Outlet Relief 3) Service brake posisi ON
Valve
Specifikasi 450 ± 70 kPa (65 ± 10
psi)

Posisi Pressure Tap

2. Torque 1) Transmisi posisi Netral
Converter 2) Engine Speed High Idle (Cold
Inlet Relief Oil)
Valve
Spesifikasi 930 + 35 kPa
(135 + 5 psi)

Posisi Pressure Tap

3. Lock Up Kondisi Pengukuran sama dengan
Clutch saat mengukur setting parking
Torque brake release pressure relief valve.
Converter
Supply Spesifikasi 4700 + 200 kPa
Pressure (680 + 30 psi )

Posisi Pressure Tap

4. Lock Up 1) Transmisi posisi Netral
Clutch Pilot 2) Engine speed Low Idle
Torque
Converter Spesifikasi 1725 + 70 kPa
(250 + 10 psi)

Posisi Pressure Tap

5. Tekanan 1) Engine Speed 1300 RPM
maksimum 2) Tranmisi Netral
lock 3) Jumper cable supply ke down

Once printed this document becomes uncontrolled. Refer to Petrosea Intranet for controlled copy.
Error! Reference source not found. Rev No. A 6 of 12
 Performance Test Caterpillar OHT 777D

up clutch shif
pressure solenoid terhadap solenoid
Test lockup
untuk mengaktifkan lockup
solenoid.

Spesifikasi 2140 + 70 kPa

(310 + 10 psi)

6. Tekanan 1) Engine Speed Low Idle RPM

primary lock 2) Tranmisi Netral
up 3) Jumper cable supply ke
clutch downshif
pressure solenoid terhadap solenoid
lockup
untuk mengaktifkan lockup
solenoid
4) Buka load piston Plug

Spesifikasi 1030 + 35 kPa

(150 + 5 psi)

Once printed this document becomes uncontrolled. Refer to Petrosea Intranet for controlled copy.
Error! Reference source not found. Rev No. A 7 of 12
 Performance Test Caterpillar OHT 777D

Testing Adjusting Transmission System

No Activity Description Visual
1. Tekanan 1) Transmisi posisi Netral
output 2) Parking Brake Posisi ON
pompa 3) Engine speed Low Idle serta High
transmisi Idle

Spesifikasi
Low Idle = 390 Psi
High Idle = 465 Psi
Lokasi Pressure Tap
2. Tekanan 1) Transmisi Posisi Netral
maksmimum 2) Parking brake posisi ON
dan minimum 3) Engine speed Low Idle dan High
transmisi Idle
lubrication
Spesifikasi
Low Idle = 0.6 psi
High Idle = 10 – 20 psi

Lokasi Pressure Tap

3. Tekanan oli 1) Transmisi posisi Netral
pilot 2) Parking Brake ON
transmisi 3) Engine speed low idle

Spesifikasi
255 + 5 psi

Lokasi Pressure Tap

4. Tekanan 1) Lepaskan hubungan main drive
Primary Clutch shaft supaya tranmisi tidak
transmisi berputar
2) Lepaskan connector solenoid
upshift
dan downshift
3) Gunakan rachet drive untuk
memindahkan gigi transmisi
secara
manual untuk mengenggagedkan
clutch
Lokasi Pressure Tap

Specifikasi (Toleransi ± 6 psi)

Speed Clutch Pressure Tap
Position Engaged (psi)
N1 1 C = 50 X

Once printed this document becomes uncontrolled. Refer to Petrosea Intranet for controlled copy.
Error! Reference source not found. Rev No. A 8 of 12
 Performance Test Caterpillar OHT 777D

N2 1 C = 50 X
R 1&7 C = 50 G = 60
1 2&6 B = 40 F = 60
2 1&6 C = 50 F = 60
3 3&6 H = 80 F = 60
4 1&5 C = 50 E = 50
5 3&5 H = 80 E = 50
6 1&4 C = 50 A = 75
7 3&4 H = 80 A = 75
5. Tekanan 1) Pasang kembali semua load
maksimum piston plug semua modulation
clutch valve
transmisi 2) Lakukan pengetesan yang sama
saat
melakukan pengetesan primary
pressure
3) Gunakan engine speed high idle Lokasi Pressure Tap
maupun low idle sesuai
permintaan pada table
pengukuran tekanan
Specifikasi Low Idle
Speed Clutch Pressure Tap
Position Engaged (psi)
N1 1 C = 425 X
R 1&7 C = 425 G=
405
1 2&6 B = 345 F=
360

Specifikasi High Idle

Speed Clutch Pressure Tap
Position Engaged (psi)
N1 1 C = 403 X
N2 1 C = 435 X
R 1&7 C = 435 G=
405
1 2&6 B = 345 F=
360
2 1&6 C = 418 F=
360
3 3&6 H = 270 F=
360
4 1&5 C = 435 E=
360
5 3&5 H = 270 E=
360
6 1&4 C = 435 A=
205
7 3&4 H = 270 A=
205

Once printed this document becomes uncontrolled. Refer to Petrosea Intranet for controlled copy.
Error! Reference source not found. Rev No. A 9 of 12
 Performance Test Caterpillar OHT 777D

Testing Adjusting Hoist & Brake System

No Activity Description Visual

1. Brake oil cooler 1. Lever hoist ditahan pada posisi
relief valve test HOLD
2. Engine speed Low Idle

Spesifikasi
586 + 14 kPa
(85 + 2 psi)

Lokasi Pressure Tap pada pompa

2. High pressure/ 1. Lever hoist ditahan pada posisi
Rise relief valve RAISE
test 2. Engine speed High Idle

Spesifikasi
18950 + 520 kPa
(2750 + 75 psi)

Lokasi Pressure Tap pada lines

Raise
3. Low 1. Lever hoist ditahan pada posisi
pressure/Lower LOWER
relief valve test 2. Engine speed High Idle

Spesifikasi
3450 ± 350 kPa
(500 ± 51 Psi)

Lokasi Pressure Tap pada lines

Lower
4. Parking Brake 1. Transmisi Netral
release relief 2. Parking Brake release lever
valve test posisi
OFF
3. Engine speed High Idle
Spesifikasi
4700 ± 200 kPa
(680 ± 30 Psi )

Lokasi Pressure Tap pada parking

brake release lines manifold R/H dan
L/H

Once printed this document becomes uncontrolled. Refer to Petrosea Intranet for controlled copy.
Error! Reference source not found. Rev No. A 10 of 12
 Performance Test Caterpillar OHT 777D

5. Brake Cooling 1. Temperature oil tercapai

Pressure 2. Engine Low Idle
3. Engine High Idle

Spesifikasi
Low Idle = Min 2 Psi (14 kPa)
High Idle = Max 25 Psi (172
kPa)
Lokasi Brake Cooling Pressure
6. Service Brake 1. Engine High Idle
Pressure 2. Service Brake diinjak

Spesifikasi
High Idle = 4323 to 5702
kPa (627 to 825 psi)

Lokasi Pressure Tap

7. Retarder Brake 1. Engine High Idle
Pressure 2. Retarder ditarik

Spesifikasi
High Idle Max = 3640 kPa (528
psi)

Lokasi Pressure Tap

8. Residual Rear 1. Tekanan udara maksimum
Brake Pressure 2. Service Brake diinjak
3. Lepas Service Brake

Spesifikasi
127 kPa (18 psi)

Lokasi Pressure Tap

Once printed this document becomes uncontrolled. Refer to Petrosea Intranet for controlled copy.
Error! Reference source not found. Rev No. A 11 of 12
 Performance Test Caterpillar OHT 777D

Testing Adjusting Steering System

No Activity Description Visual

1. Primary 1. Temperature oil tercapai
Steering 2. Engine Low Idle
Pressure
Low Pressure Spesifikasi
Standby (Low 2510 ± 440 kPa (364 ± 64 psi)
Idle)

Lokasi Pressure Tap (SS)

2. Primary 1. Temperature oil tercapai
Steering 2. Engine Low Idle
Pressure
High Pressure Spesifikasi
Cut Off Setting 21270 ± 350 kPa (3100 ± 50
(High Idle) psi)

Lokasi Pressure Tap (SS)

3. Secondary 1. Temperature oil tercapai
Steering 2. Parking Brake Off
Pressure Relief 3. Aktifkan Secondary Steering
Setting Pump
(Secondary
Steering Pump Spesifikasi
ON) 17225 ± 350 kPa (2498 ± 51
psi)

Lokasi Pressure Tap (SS)

Once printed this document becomes uncontrolled. Refer to Petrosea Intranet for controlled copy.
Error! Reference source not found. Rev No. A 12 of 12