- Off Highway Truck
- 777F (S/N: JRP1-UP)
Introduction
Revision | Summary of Changes in REHS3436 |
05 | Change Labels in Table 12.
Add Notes. Change Values in Tables 8 and 10. Standardized. |
04 | Updated Introduction.
Corrected part numbers for Adapter Cable As in Table 3. |
03 | Updated graphics, corrected part numbers for Adapter Cable As (Test) to Table 3. |
02 | Added new introduction and Canceled Part Numbers section, and corrected lube check test procedure and table. |
© 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
Machine Model | Transmission Arrangement |
777F |
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.
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 3 were used to develop this test procedure.
Required Tools | |||
---|---|---|---|
Tool | Part Number | Part Description | Qty |
A | Rail As | 2 | |
B | Plate As (Spindle Adapter) | 1 | |
Bolt (3/4-10X2.5 inch) | 2 | ||
Hard Washer | 2 | ||
Full Nut | 2 | ||
90o Pipe Street Elbow | 1 | ||
Pipe Nipple | 1 | ||
C | Swivel Head Support Gp | 1 | |
D | Drive Adapter | 1 | |
Bolt (5/8-18X1.75 inch) | 4 | ||
Lockwasher | 4 | ||
E | Drive Adapter (Key)(1) | 1 | |
F | Drive Adapter(2) | 1 | |
G | Link Bracket As | 1 | |
Bolt (1/2-13X1.75 inch) | 1 | ||
Hard Washer | 1 | ||
H | Load Binder As (Ratchet Type) | 3 | |
J | Adapter (Splined) | 1 | |
K | Spindle Gp | 1 | |
Bolt (1/2-13X2.0 inch) | 4 | ||
Lockwasher | 4 | ||
L | Fitting | 1 | |
Adapter | 1 | ||
Half Flange | 2 | ||
Fitting As (Plain) | 1 | ||
Fitting As (Quick Disconnect) | 1 | ||
O-Ring Seal | 1 | ||
Bolt (7/16-14x1.5 inch) | 4 | ||
Hard Washer | 4 | ||
M | Fitting | 1 | |
Adapter | 1 | ||
Half Flange | 2 | ||
Fitting As (Plain) | 1 | ||
Fitting As (Quick Disconnect) | 1 | ||
O-Ring Seal | 1 | ||
Bolt (7/16-14x1.5 inch) | 4 | ||
Hard Washer | 4 | ||
N | Manifold | 1 | |
Bolt (5/16-18X5.0 inch) | 4 | ||
Connector | 1 | ||
O-Ring Seal | 1 | ||
Nipple (Pipe) | 1 | ||
Elbow | 1 | ||
P | Test Cover | 1 | |
Bolt (3/8-16X.75 inch) | 26 | ||
Q | Fitting | 1 | |
Nipple (Plain) | 1 | ||
Bushing (Reducing) | 1 | ||
R | 277-2362 | Electronic Control Gp | 1 |
305-7401 | Adapter Cable As (Test) | 1 | |
306-0397 | 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. |
Installation Procedure
- Install Tooling (A) on the rails of the test bench.
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Illustration 4 g01319482 - Remove threaded plug (1).
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Illustration 5 g01319484 - Install Tooling (B).
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Illustration 6 g01319487 - Install Tooling (C) to Tooling (B).
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Illustration 7 g01319488 - Use a hoist to install the transmission on the test bench. The weight of the transmission is
1588 kg (3500 lb) .Show/hide tableIllustration 8 g01319531 - Install Tooling (D) to the input yoke.
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Illustration 9 g01319532 - Install Tooling (E) on Tooling (D).
Note: Tooling (E) will adapt to the small drive shaft, install Tooling (F) on Tooling (D).
Show/hide tableIllustration 10 g01319533 - Align the transmission with the input drive shaft.
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Illustration 11 g00891020 - Close and latch the drive shaft guard.
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Illustration 12 g03802221 - Tighten all four castle nuts and jack bolts.
- Connect the input drive shaft to Tooling (E).
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Illustration 13 g01319543 - Install Tooling (G) to the input end of the transmission.
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Illustration 14 g01319545 Show/hide tableIllustration 15 g01319550 - Install Tooling (H).
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Illustration 16 g01319579 - Install Tooling (J).
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Illustration 17 g01319581 - 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.
Show/hide tableIllustration 18 g01319583 - Loosen bolt (2).
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Illustration 19 g01319585 - Use bolt (3) to adjust Tooling (K) inward until Tooling (K) contacts the carrier. Tooling (K) will slide into Tooling (J).
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Illustration 20 g01319586 - Tighten the collet on Tooling (K) to connect Tooling (K) to Tooling (J).
- Adjust Tooling (K) 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).
- Tighten bolt (2).
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Illustration 21 g01319665 - Remove cover (4).
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Illustration 22 g01319611 - Install Tooling (L).
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Illustration 23 g01319612 - Install Tooling (M).
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Illustration 24 g01319614 - Remove cover (5).
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Illustration 25 g01319615 - Remove oil lines (6) from valve (7).
- Remove valve (7).
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Illustration 26 g01319619 - Install Tooling (N).
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Illustration 27 g01319621 - Install valve (7) to Tooling (N).
- Install oil lines (6) to valve (7).
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Illustration 28 g01319698 - Install Tooling (P).
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Illustration 29 g01319699 - Install Tooling (Q).
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Illustration 30 g01319715 (8) Transmission Supply Oil - Connect Hose Assembly (8) from the pressurized flow meter on the test bench to Tooling (L).
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Illustration 31 g01319716 - Connect Hose Assembly (9) from Tooling (Q) to the No. 2 flow meter inlet.
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Illustration 32 g01319718 - Connect Hose Assembly (10) from the No. 2 flow meter outlet to Tooling (M).
Note: The "No. 2" flow meter will measure the lube flow.
Show/hide tableIllustration 33 g01319719 - 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) .Show/hide tableIllustration 34 g01319720 (12) System Pressure - Connect a pressure gauge to test port (12).
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Illustration 35 g01319722 (13) Input Transfer Gear Lube Pressure - Connect a pressure gauge to test port (13).
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Illustration 36 g01319723 (14) Lubrication Pressure - Connect a pressure gauge to test port (14).
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Illustration 37 g01319724 (15) No. 6 Clutch Pressure
(16) No. 5 Clutch Pressure
(17) No. 7 Clutch Pressure
(18) No. 4 Clutch Pressure
(19) No. 3 Clutch Pressure
(20) No. 2 Clutch Pressure
(21) No. 1 Clutch Pressure - Connect a pressure gauge to each of the clutch pressure taps (15), (16), (17), (18), (19), (20), and (21).
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Illustration 38 g02629190 Tooling (R) - Install Tooling (R).
Note: Refer to Tool Operating Manual, NEHS0966 for the correct operating instructions.
Illustration 3 | g01319479 |
TA3 Navigation
- Select “Off-Highway Trucks”.
- Select “777F-24V”.
Harness Test
- Make sure that the harness is properly connected.
- Use Tooling (R) to perform the harness test.
- Record the values in Table 6.
Note: Do not continue testing until Harness Test passes.
Start Checks
Note: Refer to Testing and Adjusting, RENR8303, "777F Off-Highway Truck Power Train" for the correct adjusting procedures.
- 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 to34 °C (95 °F) . Maintain this temperature for the duration of the test. - Adjust the input flow to
170 ± 4 L/min (45 ± 1 US gpm) .Show/hide tableIllustration 39 g02720621 - 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.
- Shift the transmission through all gears to eliminate air from the transmission controls.
- Confirm the correct 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 CL 6 CL 7 N X R X X F1 X X F2 X X F3 X X F4 X X F5 X X F6 X X F7 X X - Stop the input rotation.
Lube Check
- Adjust the lube flow to
151 ± 4 L/min (40 ± 1 US gpm) . - Adjust the input rotation to 1925 ± 10 rpm.
- Shift the transmission to the FORWARD 2 position.
- Record the lubrication pressure in Table 7.
- The lubrication pressure must be
62 ± 14 kPa (9 ± 2 psi) .
Pressure Check (Low Idle)
- Adjust the input flow to
108 ± 4 L/min (29 ± 1 US gpm) . - Adjust the input rotation to 800 ± 10 rpm.
- Shift the transmission through ranges REVERSE, NEUTRAL, FORWARD 1, FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, and FORWARD 7.
Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.
- Record the clutch pressure for each range in Table 9.
- Verify that the clutch pressures match the values in Table 8.
Pressure Check (High Idle)
- Adjust the input flow to
170 ± 4 L/min (45 ± 1 US gpm) . - Adjust the input rotation to 1925 ± 10 rpm.
- Shift the transmission through ranges REVERSE, NEUTRAL, FORWARD 1, FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, and FORWARD 7.
Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.
Note: Return to low idle rpm before shifting between gears.
- Record the clutch pressure for each range in Table 11.
- Verify that the clutch pressures match the values in Table 10.
Clutch Leakage Check
- Adjust the input flow to
170 ± 4 L/min (45 ± 1 US gpm) . Maintain this flow for the duration of this check. - Shift the transmission to the NEUTRAL position.
- Adjust the input rotation to 1925 ± 10 rpm.
- Record the supply pressure in Table 13. The correct supply pressure is
2965 ± 35 kPa (430 ± 5 psi) . - Record the input flow in Table 13.
- Record the cooler flow in Table 13.
- The leakage is obtained by subtracting the cooler flow from the input flow.
- Record the calculation in Table 13.
- Adjust the input rotation to 800 ± 10 rpm.
- 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.
Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.
- Verify that the clutch leakages match the values in Table 12.
Note: Subtract the clutches for the gears called out, eliminating the common clutch.
EXAMPLE:
F2 uses CL1 and CL 6
F1 uses CL 2 and CL 6
F2 - F1 (CL 1,6 - CL 2,6)
(eliminate common clutch: CL 6) = CL 1 - CL 2
Contamination Control
- Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.
- Record the results in Table 14.
- Remove the transmission from the test bench if the test bench oil supply is within specifications.
Transmission Bench Test Data Sheet
CATERPILLAR | Transmission Bench Test Data Sheet | Test Date:__________ |
Model:__________ | ||
Work Order:__________ | Serial No.:__________ |
Harness Test
Harness Test | Solenoid 1 | Solenoid 2 | Solenoid 3 | Solenoid 4 | Solenoid 5 | Solenoid 6 | Solenoid 7 |
__________ ohms |
__________ ohms |
__________ ohms |
__________ ohms |
__________ ohms |
__________ ohms |
__________ ohms |
Lube Check
Lube Check |
Input Speed (1925 ± 10 rpm) | |
Gear Range | Lubrication Pressure | |
FORWARD 2 |
__________kPa __________(psi) |
Pressure Check (Low Idle)
Pressure Check (Low Idle) | ||||||||
---|---|---|---|---|---|---|---|---|
Gear | Engaged Clutches | CL 1(1) | CL 2(1) | CL 3(1) | CL 4(1) | CL 5(1) | CL 6(1) | CL 7(1) |
N | 1 | |
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R | 1 and 7 | |
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F1 | 2 and 6 | |
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F2 | 1 and 6 | |
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F3 | 3 and 6 | |
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F4 | 1 and 5 | |
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F5 | 3 and 5 | |
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F6 | 1 and 4 | |
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F7 | 3 and 4 | |
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(1) | The tolerance is |
Pressure Check (Low Idle) | Input Speed (800 ± 10 rpm) | ||||||||
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Gear | Active Clutches | CL 1 | CL 2 | CL 3 | CL 4 | CL 5 | CL 6 | CL 7 | |
N | 1 | - | |||||||
R | 1 | 7 | |||||||
F1 | 2 | 6 | |||||||
F2 | 1 | 6 | |||||||
F3 | 3 | 6 | |||||||
F4 | 1 | 5 | |||||||
F5 | 3 | 5 | |||||||
F6 | 1 | 4 | |||||||
F7 | 3 | 4 |
Pressure Check (High Idle)
Pressure Check (High Idle) | ||||||||
---|---|---|---|---|---|---|---|---|
Gear | Engaged Clutches | CL 1(1) | CL 2(1) | CL 3(1) | CL 4(1) | CL 5(1) | CL 6(1) | CL 7(1) |
N | 1 | |
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R | 1 and 7 | |
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F1 | 2 and 6 | |
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F2 | 1 and 6 | |
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F3 | 3 and 6 | |
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F4 | 1 and 5 | |
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F5 | 3 and 5 | |
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F6 | 1 and 4 | |
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F7 | 3 and 4 | |
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(1) | The tolerance is |
Pressure Check (High Idle) | Input Speed (1925 ± 10 rpm) | ||||||||
---|---|---|---|---|---|---|---|---|---|
Gear | Active Clutches | CL 1 | CL 2 | CL 3 | CL 4 | CL 5 | CL 6 | CL 7 | |
N | 1 | - | |||||||
R | 1 | 7 | |||||||
F1 | 2 | 6 | |||||||
F2 | 1 | 6 | |||||||
F3 | 3 | 6 | |||||||
F4 | 1 | 5 | |||||||
F5 | 3 | 5 | |||||||
F6 | 1 | 4 | |||||||
F7 | 3 | 4 |
Clutch Leakage Check
Clutch Leakage Check | |||
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Clutch | Gears | Minimum Value | Maximum Value |
CL 1 | F2 - F1 | |
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F2 - F3 | |
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F4 - F5 | |
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F6 - F7 | |
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CL 2 | F1 - F2 | |
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F1 - F3 | |
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CL 3 | F3 - F1 | |
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F3 - F2 | |
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F5 - F4 | |
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F7 - F6 | |
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CL 4 | F6 - R | |
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F6 - F2 | |
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F6 - F4 | |
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F7 - F3 | |
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F7 - F5 | |
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CL 5 | F4 - R | |
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F4 - F2 | |
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F4 - F6 | |
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F5 - F3 | |
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F5 - F7 | |
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CL 6 | F2 - R | |
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F2 - F4 | |
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F2 - F6 | |
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F3 - F5 | |
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F3 - F7 | |
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CL 7 | R - F2 | |
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R - F4 | |
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R - F6 | |
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Note: Subtract the clutches for the gears called out, eliminating the common clutch.
EXAMPLE:
F2 uses CL1 and CL 6
F1 uses CL 2 and CL 6
F2 - F1 (CL 1,6 - CL 2,6)
(eliminate common clutch: CL 6) = CL 1 - CL 2
Clutch Leakage Check | Input Speed (1925 ± 10 rpm)
Input Flow |
||||||||
---|---|---|---|---|---|---|---|---|---|
Gear Range | N | R | F1 | F2 | F3 | F4 | F5 | F6 | F7 |
Supply Pressure | ______ |
______ |
______ |
______ |
______ |
______ |
______ |
______ |
______ |
Input Flow | ______ |
______ |
______ |
______ |
______ |
______ |
______ |
______ |
______ |
Cooler Flow | ______ |
______ |
______ |
______ |
______ |
______ |
______ |
______ |
______ |
Leakage | ______ |
______ |
______ |
______ |
______ |
______ |
______ |
______ |
______ |
Average of Arrangement | ______ |
______ |
______ |
______ |
______ |
______ |
______ |
______ |
______ |
Contamination Control
ISO Particle Count | Sample the test bench oil supply. *ISO 4406 is 16/13 or better |
________/________Particle Count |
______________________________________ Technician |
______________________________________ Supervisor |