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Procedimientos de prueba de bancoBench Test Procedure For A 777F Off-Highway Truck Transmission{3030, 3073}

Bench Test Procedure For A 777F Off-Highway TruckTransmission{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 specifictransmission arrangements. Refer to Table 1 for the correct arrangements. Bench testing thetransmission 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 willoperate properly in the machine. The specifications in this guideline are specific to bench testing thecomponent. Every effort has been made in order to provide the most current information that is knownto Caterpillar. Continuing improvement and advancement of product design might have caused changesto your product which are not included in this publication. This guideline must be used with the latesttechnical information that is available from Caterpillar.

Collecting the Test Data

Since conditions vary for each test bench, it is important to use the data that is collected from your testbench. The collected data is used to compare test results. The data should be collected and maintainedby the operator.

Data from each transmission arrangement is collected and stored. Averages from each transmissionarrangement are often used in order to compare values on portions of transmission tests. Alwayscompare data that is collected from the same transmission arrangement that is being tested. Averagesfor the last 20 transmission arrangements should be maintained.

Cerrar SIS

Pantalla anterior

Producto: TRUCKModelo: 777F TRUCK JRP

Configuracin: 777F Off-Highway Truck JRP00001-UP (MACHINE)POWERED BY C32 Engine

Nmero de medio -REHS3436-00 Fecha de publicacin -08/03/2007 Fecha de actualizacin -08/03/2007

i02630853

Table 1

Machine Model Transmission Arrangement

777F 246-2647

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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 inorder to develop this test procedure.

Personal injury or death can result from escaping fluid under pressure.

Escaping fluid under pressure, even a very small pin-hole size leak, canpenetrate body tissue and cause serious injury and possible death. If

fluid is injected into your skin, it must be treated immediately by adoctor 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 properprocedures.

To avoid the possibility of injury or death, follow the establishedprocedure.

Table 2

Required Tools

Tool Part Number Part Description Qty

A 1U-9584 Rail As 2

B

1U-5810 Plate As (Spindle Adapter) 1

1A-8063 Bolt (3/4-10X2.5 inch) 2

5P-8248 Hard Washer 2

2J-3506 Full Nut 2

9F-2535 90oPipe Street Elbow 1

140-7299 Pipe Nipple 1




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Installation Procedure

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

N

1F-6296 Bolt (5/16-18X5.0 inch) 4

061-8246 Connector 1

1S-7462 O-Ring Seal 1

004-7270 Nipple (Pipe) 1

3B-6554 Elbow 1

P305-7491 Test Cover 1

0S-0509 Bolt (3/8-16X.75 inch) 26

Q

6L-5295 Fitting 1

7X-7646 Nipple (Plain) 1

6B-9081 Bushing (Reducing) 1

R277-2363 Electronic Control Gp 1

305-7401 Adapter Cable As (Test) 1

( 1 ) This drive adapter is used with the small drive shaft.

( 2 ) This drive adapter is used with the large drive shaft.

Illustration 1 g01319479




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2. Remove threaded plug (1) .

3. Install Tooling (B) .






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

5. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1587.6kg (3500 lb).






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

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 willbe necessary to install Tooling (F) on Tooling (D) .






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8. Align the transmission with the input drive shaft.

9. Connect the input drive shaft to Tooling (E) .

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






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11. Install Tooling (H), as shown.






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12. Install Tooling (J) .

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 SpindleGroup Used for Testing Transmissions on Hydraulic Test Bench" for additional information.



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14. Loosen bolt (2) .

15. Use bolt (3) to adjust Tooling (K) inward until Tooling (K) contacts the carrier. Tooling (K) willslide into Tooling (J) .






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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 betweenTooling (K) and the carrier.

Note: The measurement may be taken through the access hole in Tooling (B) .

18. Tighten bolt (2) .

19. Remove cover (4) .






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20. Install Tooling (L) .

21. Install Tooling (M) .






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22. Remove cover (5) .

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

24. Remove valve (7) .






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25. Install Tooling (N) .

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

27. Install oil lines (6) to valve (7) .






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28. Install Tooling (P) .

29. Install Tooling (Q) .






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30. Connect Hose Assembly (8) from the pressurized flow meter on the test bench to Tooling (L) .

31. Connect Hose Assembly (9) from Tooling (Q) to the inlet of the "Number 2" flow meter.


(8) Transmission Supply Oil





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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.

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).






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34. Connect a pressure gauge to test port (12) .



(12) System Pressure


(13) Input Transfer Gear Lube Pressure




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(14) Lubrication Pressure


(15) No. 6 Clutch Pressure








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37. Connect a pressure gauge to each of the clutch pressure taps (15), (16), (17), (18), (19), (20), and(21) .

38. Install Tooling (R).




Tooling (R)





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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 thecorrect 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).

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwisedirection. 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 airfrom the transmission controls.





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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, FORWARD3, FORWARD 4, FORWARD 5, FORWARD 6, and FORWARD 7. Repeat Steps 4 through 5 foreach 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

Pressure Check (Low Idle)

ClutchNo.

1 (1)No.

2 (1)No.

3 (1)No.

4 (1)No.

5 (1)No.

6 (1)No.

7 (1)

Speed RangeEngaged

Clutches Pressure

REVERSE1 and 7 2765

kPa2820kPa




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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 theduration 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 2through 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.

FORWARD5

3 and 5

2324kPa(337

psi)

2124kPa(308

psi)

FORWARD6

1 and 42813kPa(408

psi)

2165kPa(314

psi)

FORWARD7

3 and 42317kPa(336

psi)

2172kPa(315

psi)

( 1 ) The tolerance is 68.9 kPa ( 10 psi).

Table 5

Clutch Leakage Check

Clutch Subtract Minimum Value Maximum Value

2 - 1-0.8 L/min (- 0.2 US gpm) 1.7 L/min (0.5 US gpm)




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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

Solenoid Test

Lube Check

6

2 - 4-1.6 L/min (-0.4 US gpm) 1.7 L/min (0.4 US gpm)

2 - 6-10.1 L/min (-2.7 US gpm) -5.0 L/min (-1.3 US gpm)

3 - 5 -1.2 L/min (-0.3 US gpm) 1.6 L/min (0.4 US gpm)

3 - 7-11.2 L/min (-3.0 US gpm) -5.7 L/min (-1.5 US gpm)

7

R - 2-1.6 L/min (-0.4 US gpm) 1.7 L/min (0.5 US gpm)

R - 4-1.1 L/min (-0.3 US gpm) 1.5 L/min (0.4 US gpm)

R - 6-10.2 L/min (-2.7 US gpm) -5.1 L/min (-1.3 US gpm)

Table 6

CATERPILLAR Transmission Bench Test Data SheetTest Date:

Model:

Work Order: Serial No.:

Table 7

SolenoidTest

Solenoid1

Solenoid2

Solenoid3

Solenoid4

Solenoid5

Solenoid6

Solenoid7

ohms ohms ohms ohms ohms ohms ohms

Table 8




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