Bench Test Procedure for a 797F Off-Highway Truck Transmission {3030, 3073, 3139} Caterpillar

Bench Test Procedure for a 797F Off-Highway Truck Transmission {3030, 3073, 3139}

Usage:

797F LAJ

Off-Highway Truck/Tractor: 797F (S/N: LAJ1-UP; WSP1-UP; LTZ1-UP)

Introduction

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Table 1
Revision	Summary of Changes in REHS3602
11	Added Serial Number Prefix LTZ. Added Arrangement 525-3960 to Table 2. Removed Arrangement 422-3795 from Table 2. Modified and Split Tables 10 through Table 17.
10	Updated Control Pressure in all Tables. Updated Table 3by Replacing FT's with Current Part Numbers. Standardized.
09	Updated Table 8 Control Supply Pressure for Transmission Arrangement 446-9392.
08	Updated media reference in Start Checks.
07	Updated Table 8. Updated Table 20.

© 2019 Caterpillar All Rights Reserved. This document 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 document 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 document 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 document must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

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Table 2
Machine Model	Transmission Arrangement
797F	272-3224, 446-9392, 525-3960.

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

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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.

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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, specifications, and illustrations that exist in this document 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.

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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.

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Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

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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

Pressures will be sensitive to tooling setup. The diameter of the hose, the diameter of a fitting, and extra filtering can affect pressure. The required tools that are listed in Table 3 were used to develop this test procedure. These tools are suggested and may vary depending on availability and bench configuration.

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Table 3
Required Tools
Tool	Part Number	Part Description	Qty
A	⁽¹⁾	Support	1
	9X-8889	Bolt (3/4-10X3.5 inch)	16
	5P-8248	Hard Washer	16
	8H-5772	Bolt (1.0-8X3.75 inch)	20
	2J-3507	Full Nut	20
	5P-8250	Washer	40
	8C-3236	Bolt (M30X3.5X160 mm)	20
	9X-8399	Washer	20
B	⁽¹⁾	Drive Adapter	1
	230-4325	Bolt (M22X1.5X50 mm)	4
	0S-1595	Bolt (1/2-13X1.25 inch)	4
	5P-8245	Hard Washer	4
C	⁽¹⁾	Adapter	1
	0S-1587	Bolt (1/2-13X1.50 inch)	12
	5P-8245	Hard Washer	12
D	⁽¹⁾	Support (Output Shaft)	1
	1A-8063	Bolt (3/4-10X2.50 inch)	8
	5P-8248	Hard Washer	8
E	472-0531	Hose As	1
F	472-0555	Hose As	1
G	472-0532	Hose As	1
H	472-0535	Hose As	1
	8T-0273	Bolt (M12X1.75X40 mm)	2
	8T-4223	Hard Washer	2
X	472-0537	Hose As	1
	095-0705	Bolt (M16X2.0X100 mm)	4
	9X-8268	Washer	4
J	472-0534	Hose As	1
	8T-7811	Bolt (M12X1.75X50 mm)	4
	5C-8815	Washer	4
K	472-0539	Hose As	1
	8T-0273	Bolt (M12X1.75X40 mm)	4
	5C-8815	Washer	4
L	472-0536	Hose As	1
	095-0705	Bolt (M12X1.75X100 mm)	4
	9X-8268	Washer	4
M	472-0538	Hose As	1
N	472-0533	Hose As	1
Y	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	7
	6V-3989	Fitting (Test)	7
	177-7861	Hose As	7
	6V-4143	Coupler	14
P	277-2362	Transmission Analyzer III Tool Gp	1
	9U-7498	Extension Cable	1
	FT-3225	Adapter Cable As	1
Q	⁽¹⁾	Data Acquisition System	1
R	⁽¹⁾	Pressure Transducer (0 to 4137 kPa (0 to 600 psi))	5
S	⁽¹⁾	Pressure Transducer (0 to 6895 kPa (0 to 1000 psi))	2
T	⁽¹⁾	Adapter (Sensor)	1
U	146-4080	Digital Multimeter (RS-232)	1
V	⁽²⁾	Vibration Data Capture System	1
W	188-0645	Particle Analyzer Gp	1

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⁽¹⁾	Contact Caterpillar Dealer Service Tools
⁽²⁾	Contact Caterpillar Technical Services Division

Software Requirement

The 797F transmission must be shifted sequentially through the gear ranges.

The 277-2362 Transmission Analyzer III will be used to shift the transmission sequentially through the gears.

Installation Procedure

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Illustration 3	g00924816

Use a hoist to install Tooling (A) on the test bench. The weight of Tooling (A) is approximately 2858 kg (6300 lb).
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Illustration 4 g00948434
Use a hoist to install the transmission on Tooling (A). The approximate weight of the transmission is 6260 kg (13800 lb).
Install 20 bolts (1). Do not install the bolts next to each other. Skip a mounting hole for each bolt. The correct torque is 1600 ± 200 N·m (1180 ± 148 lb ft).
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Illustration 5 g00948435
Install Tooling (B) to the input yoke.
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Illustration 6 g00948436
Align the transmission with the input drive shaft.
Connect the input drive shaft to Tooling (B).
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Illustration 7 g00948439
Install the drive shaft guard.
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Illustration 8 g00948440
Install the extension for the drive shaft guard.
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Illustration 9 g00948441
Use a hoist to install Tooling (C). The weight of Tooling (C) is 85 kg (187 lb).
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Illustration 10 g00948442
Use a hoist to install Tooling (D). The weight of Tooling (D) is 549 kg (1210 lb).
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Illustration 11 g00948446
Connect Tooling (E) to the auxiliary oil tank.
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Illustration 12 g00948447
Connect Tooling (E) to the test bench, as shown.
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Illustration 13 g00948448

"Bearing Lube"
Connect Tooling (F) to the auxiliary oil tank.
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Illustration 14 g00948449
Connect Tooling (F) to Tooling (D). Maintain an oil pressure of 275 kPa (40 psi).
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Illustration 15 g00948452
Install Tooling (G) on the transmission.
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Illustration 16 g00948453
Remove ecology drain (2).
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Illustration 17 g00948454
Install Tooling (H).
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Illustration 18 g00948456

Note: Tooling (H) is used as a sight gauge.
Insert Tooling (H) into bolt hole, as shown.
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Illustration 19 g03359768

"Transmission Control Supply"
Connect Tooling (X) to the auxiliary oil tank.
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Illustration 20 g03359776
Connect Tooling (X) to the transmission.
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Illustration 21 g00948460

"Transmission Lube Supply"
Connect Tooling (J) to the auxiliary oil tank.
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Illustration 22 g00948461
Connect Tooling (J) to the transmission.
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Illustration 23 g00948462

"Transmission Control Return"
Connect Tooling (K) to the auxiliary oil tank.
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Illustration 24 g02022787
Connect Tooling (K) to the transmission.
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Illustration 25 g00948464

"Scavenge Inlet"
Connect Tooling (L) to the auxiliary oil tank.
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Illustration 26 g00948467
Connect Tooling (L) to the transmission.
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Illustration 27 g00948468
Install Tooling (M) on the transmission.
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Illustration 28 g00948469

Install Tooling (N) on the transmission.

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Illustration 29	g02029332
(3) Pressure tap "CLUTCH 7" (4) Pressure tap "CLUTCH 1" (5) Pressure tap "CLUTCH 4" (6) Pressure tap "CLUTCH 5" (7) Pressure tap "CLUTCH 3" (8) Pressure tap "CLUTCH 2" (9) Pressure tap "CLUTCH 6"

Note: If you are using individual pressure gauges to measure the pressures, refer to Table 3 for the correct pressure gauges.

Connect Tooling (Y) to pressure taps (3), (4), (5), (6), (7), (8), and (9), as shown.
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Illustration 30 g00948472

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Illustration 31 g06409534
Connect Tooling (P) to the transmission harness, and to a power source. Refer to Tool Operating Manual, NEHS0996 for the correct operating instructions.
Note: The following Steps are for connecting Tooling (Q) to the transmission.
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Illustration 32 g00948475

Tooling (Q)

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Illustration 33 g00987122
Open the front panel of the test bench.
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Illustration 34 g00987123
Connect signal cable (10) and signal cable (11) to the test bench.
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Illustration 35 g00948479

(10) "Pressure 13" Horsepower from the Hydraulic Test Bench
(11) "Pressure 14" Input Speed from the Hydraulic Test Bench
Connect signal cable (10) and signal cable (11) to Tooling (Q).
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Illustration 36 g00948481

"Control Return Flow"
Connect signal cable (12) to the control panel for the auxiliary oil tank.
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Illustration 37 g00948482

(12) "Flow 4" For The Transmission Control Return Flow
Connect signal cable (12) to Tooling (Q).
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Illustration 38 g00948486

"Control Supply Flow"
Connect signal cable (13) to the control panel for the auxiliary oil tank.
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Illustration 39 g00948488

(13) "Flow 3" Input Flow For The Transmission Control
Connect signal cable (13) to Tooling (Q).
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Illustration 40 g00948492

"Lube Supply Flow"
Connect signal cable (14) to the control panel for the auxiliary oil tank.
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Illustration 41 g00948494

(14) "Flow 2" Flow For Transmission Lubrication Oil
Connect signal cable (14) to Tooling (Q).
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Illustration 42 g00948495
Connect signal cable (15) to Tooling (D).
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Illustration 43 g00948499

(15) "Flow 8" For The Output Speed
Connect signal cable (15) to Tooling (Q).
Connect signal cable (16) to Tooling (R).
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Illustration 44 g02022823

Transmission Control Return Pressure
Connect Tooling (S) to the pressure tap for the transmission control return pressure.
Connect signal cable (17) to Tooling (S).
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Illustration 45 g00948510

(17) "Pressure 10" Transmission Control Return Pressure
Connect signal cable (17) to Tooling (Q).
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Illustration 46 g00948513

Lubrication Pressure (Rear Module)
Connect Tooling (R) to the pressure tap for the rear module lube pressure.
Connect signal cable (18) to Tooling (R).
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Illustration 47 g00948518

(18) "Pressure 3" Lubrication Pressure (Rear Module)
Connect signal cable (18) to Tooling (Q).
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Illustration 48 g02029345

Pressure For The Transmission Lubrication Oil
Connect Tooling (R) to the pressure tap for the transmission lubrication oil.
Connect signal cable (19) to Tooling (R).
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Illustration 49 g00948522

(19) "Pressure 2" Pressure For The Transmission Lubrication Oil
Connect signal cable (19) to Tooling (Q).
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Illustration 50 g00948523

Flow Meter For The Lubrication Flow (Front Module)
Connect signal cable (20) to Tooling (G).
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Illustration 51 g00948525

(20) "Flow 1" Lubrication Flow (Front Module)
Connect signal cable (20) to Tooling (Q).
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Illustration 52 g02029350

Lubrication Pressure (Front Module)
Connect Tooling (R) to the pressure tap for the lubrication pressure (front module).
Connect signal cable (21) to Tooling (R).
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Illustration 53 g00948528

(22) "Pressure 5" Lubrication Pressure (Front Module)
Connect signal cable (21) to Tooling (Q).
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Illustration 54 g00948531

Transmission Control Supply Pressure
Connect Tooling (R) to the pressure tap for the transmission control supply pressure.
Connect signal cable (22) to Tooling (R).
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Illustration 55 g00948535

(22) "Pressure 1" Transmission Control Supply Pressure
Connect signal cable (22) to Tooling (Q).
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Illustration 56 g00948536

Flow Meter For The Lockup Clutch Oil
Connect signal cable (23) to Tooling (M).
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Illustration 57 g00948538

(23) "Flow 5" Lockup Supply Flow
Connect signal cable (23) to Tooling (Q).
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Illustration 58 g00948542

Lockup Supply Pressure
Connect Tooling (S) to Tooling (M).
Connect signal cable (24) to Tooling (S).
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Illustration 59 g00948544

(24) "Pressure 15" Lockup Supply Pressure
Connect signal cable (24) to Tooling (Q).
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Illustration 60 g00948546

(25) "Flow 7" Input For The Intermediate Speed Sensor
Connect signal cable (25) from Tooling (P) to Tooling (Q).
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Illustration 61 g00953520

(26) "Lube Pressure"
(27) "Lube Temp"
(28) "Latch Pressure"

Note: Tooling (T) and Tooling (U) are used to measure the duty cycle of three internal sensors.
Connect signal cables (26), (27), and (28) from Tooling (P) to Tooling (T).
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Illustration 62 g00987124
Connect Tooling (U) to Tooling (T).
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Illustration 63 g00948550

(29) Signal Cables
(30) "Channel 1"
(31) "Channel 2"
(32) "Channel 3"
(33) "Channel 4"
(34) "Channel 5"
(35) "Channel 6"
Connect six signal cables (29) to Tooling (V), as shown.
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Illustration 64 g02029424

(30) "Channel 1"
(31) "Channel 2"
(32) "Channel 3"
(33) "Channel 4"
(34) "Channel 5"
(35) "Channel 6"

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Illustration 65 g02029427

(30) "Channel 1"

Note: The accelerometers must be placed in the locations, as shown. Ensure that the accelerometer is mounted on a stable surface. Refer to Illustration 65 for additional information.
Install the "Channel 1" accelerometer (30) to the transmission case, as shown.
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Illustration 66 g00948556

(31) "Channel 2"
Install the "Channel 2" accelerometer (31) to the transmission case, as shown.
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Illustration 67 g02029438

(32) "Channel 3"
Install the "Channel 3" accelerometer (32) to the transmission case, as shown.
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Illustration 68 g00948561

(33) "Channel 4"
Install the "Channel 4" accelerometer (33) to the transmission case, as shown.
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Illustration 69 g00948565

(34) "Channel 5"
Install the "Channel 5" accelerometer (34) to the transmission case, as shown.
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Illustration 70 g00948568

(35) "Channel 6"
Install the "Channel 6" accelerometer (35) to the transmission case, as shown.
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Illustration 71 g00948569

(W) Portable S2 Particle Analyzer

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Illustration 72 g00948570
Connect Tooling (W) to the transmission, as shown.

Test Procedure

Note: The transmission main relief valve MUST BE tested before the transmission can be tested. Refer to Bench Test Procedure, REHS1347, "Bench Test Procedure For The 797 and 797B Off-Highway Truck Transmission Main Relief Valve and Torque Converter Relief Valves".

TA3 Navigation

Select “Off Highway Trucks”.
Select “797F-24V”.

Harness Test

Make sure that the harness is properly connected.
Use Tooling (P) to perform the harness test.
Record the values in Table 9.
Note: Do not continue testing until Harness Test passes.

Preliminary Checks

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Table 4
Oil Requirements For Test Bench
Oil Viscosity	SAE 10W
Oil Temperature	49 °C (120 °F) to 54 °C (130 °F)
ISO Particle Count	16/13

Note: For additional information refer to Specifications KENR8369, Systems Operation , KENR8370, and Testing and Adjusting , KENR9371, "797F Off-Highway Truck Power Train".

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NOTICE

Never rotate the transmission in the state of no clutch neutral, rear box neutral, or multiple clutch tie up. Operating the transmission in any of these conditions can damage internal parts of the transmission. The transmission must be operated with the correct clutches engaged or disengaged to prevent damage to the transmission.

Warm the supply oil in the auxiliary oil tank to 50 °C (125 °F). Refer to the documentation that is provided with your equipment.
Note: Multigrade oil is NOT permitted.
The input rotation MUST BE 0 rpm.
Adjust the input flow for the transmission control to 326 ± 8 L/min (86 ± 2 US gpm).
Adjust the input flow for the transmission lubrication oil to 606 ± 12 L/min (160 ± 3 US gpm).

For Arrangement 272-3224 verify test points with the values in Table 5. For Arrangement 446-9392 and 525-3960 verify test points with the values in Table 6 before proceeding with the test.

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Table 5
Preliminary Checks for 272-3224
Test Point	Minimum	Maximum
Transmission Control Supply Pressure	2551 kPa (370 psi)	2758 kPa (400 psi)
Pressure for the Transmission Lubrication Oil	448 kPa (65 psi)	614 kPa (89 psi)
Lubrication Pressure (Front Module)	393 kPa (57 psi) 262 kPa (38 psi)⁽¹⁾	515 kPa (75 psi) 607 kPa (88 psi)⁽¹⁾
Lubrication Pressure (Rear Module)	0 172 kPa (25 psi)⁽¹⁾	69 kPa (10 psi) 427 kPa (62 psi)⁽¹⁾

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⁽¹⁾	Without Lube Diverter

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Table 6
Preliminary Checks for 446-9392 and 525-3960
Test Point	Minimum	Maximum
Transmission Control Supply Pressure	2551 kPa (370 psi)	2758 kPa (400 psi)
Pressure for the Transmission Lubrication Oil	483 kPa (70 psi)	621 kPa (90 psi)
Lubrication Pressure (Front Module)	359 kPa (52 psi)	483 kPa (70 psi)
Lubrication Pressure (Rear Module)	0	69 kPa (10 psi)

Clutch Engagement Check

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Illustration 73	g02720621

Note: The input shaft will be rotated in a counterclockwise direction during this test. The direction is determined as you face the drive motor of the test bench.

Note: Tooling (P) has been programmed to ensure that the transmission is shifted sequentially into gear ranges. The functionality of some of the input keys has been changed to ensure the requirements of this procedure.

With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 400 ± 10 rpm.
Note: If there is no lube pressure after 30 seconds, stop input rotation and check connections on test bench and transmission.
Shift the transmission through all gear ranges to eliminate air from the system.
Note: Always shift transmission to Neutral when shifting between Forward to Reverse.

Verify the correct clutch engagement with Table 7.

Note: The active clutches must match before proceeding with the test.

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Table 7
Clutch Engagement Check
Gear	CL1	CL2	CL3	CL4	CL5	CL6	CL7
R		X					X
N		X
F1			X			X
F2		X				X
F3	X					X
F4		X			X
F5	X				X
F6		X		X
F7	X			X