2002/08/26 Correction to Testing and Adjusting , "Specifications (Power Train)" {3000} Caterpillar


Correction to Testing and Adjusting , "Specifications (Power Train)" {3000}
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2002/08/26 [SEPD0644]
POWER TRAIN
TORQUE CONVERTER GP
2002/08/26 Correction to Testing and Adjusting , "Specifications (Power Train)" {3000}
Off-Highway Truck:
69D (S/N: 9XS1-UP)
769D (S/N: BBB1-UP; 5SS1-UP)
771D (S/N: BCA1-UP; 6YS1-UP)
Testing and Adjusting, SENR1550, "69D and 769D Off-Highway Truck and 771D Quarry Truck Power Train", "Specifications (Power Train)". This module is part of Service Manual, SENR1545 and part of Service Manual, RENR3386.

There are currently two sections with the title "Specifications (Power Train)" in this module. One section is effective for 769D (S/N: 5SS) Off-Highway Truck, 69D (S/N: 9XS) Off-Highway Truck, and 771D (S/N: 6YS) Quarry Truck. The other section is effective for 769D (S/N: BBB) Off-Highway Truck and 771D (S/N: BCA) Quarry Truck. These sections have been combined and revised. Replace both "Specifications (Power Train)" sections with the following information.

Table 1
Shift Points At Nominal Engine Speed    
Upshift     Engine Speed     Transmission Output Speed    
1C to 1L     1440 ± 50     306    
1L to 2     2100 ± 30     447    
2 to 3     2100 ± 30     611    
3 to 4     2100 ± 30     828    
4 to 5     2100 ± 30     1113    
5 to 6     2100 ± 30     1510    
6 to 7     2100 ± 30     2036    
Downshift     Engine Speed     Transmission Output Speed    
7 to 6     1465 ± 30     1926    
6 to 5     1465 ± 30     1420    
5 to 4     1465 ± 30     1053    
4 to 3     1465 ± 30     777    
3 to 2     1465 ± 30     578    
2 to 1L     1465 ± 30     426    
1L to 1C     1300 ± 30     276    

Table 2
Maximum Travel Speeds At 2100 RPM
(18.00-R33 Tires)    
Gear     Speed    
R    
14.7 km/h (9.1 mph)    
1    
11.2 km/h (6.9 mph)    
2    
15.4 km/h (9.5 mph)    
3    
20.8 km/h (12.9 mph)    
4    
28.0 km/h (17.6 mph)    
5    
38.0 km/h (23.6 mph)    
6    
51.2 km/h (31.7 mph)    
(1)    
69.4 km/h (43.1 mph)    
( 1 ) This speed is not used on the 771D Quarry Trucks.

Specifications for the Torque Converter

Outlet Relief Valve

Pressure setting for the outlet relief valve ... 414 ± 34 kPa (60 ± 5 psi)

Torque converter outlet pressure at stall speed ... 414 ± 34 kPa (60 ± 5 psi)

Torque converter stall speed at operating temperature ... 1906 ± 65 rpm

Table 3
Spacer Chart For The Outlet Relief Valve    
Pt. No. for the Spacers     Thickness of the Spacers     Change in Pressure as a Result of One Spacer    
5M-9624 Spacer    
0.25 mm (0.01 inch)    

5 kPa (0.73 psi)    
5M-9623 Spacer    
0.90 mm (0.035 inch)    

18 kPa (2.61 psi)    
5M-9622 Spacer    
1.60 mm (0.063 inch)    

31 kPa (4.50 psi)    

Inlet Relief Valve

Pressure setting for the inlet relief valve ... 955 ± 95 kPa (139 ± 14 psi)

Table 4
Spacer Chart for the Inlet Relief Valve    
Pt. No. for the Spacers     Thickness of the Spacers     Change in Pressure as a result of one Spacer    
145-0107 Spacer    
1.6 mm (0.063 inch)    

31 kPa (4.5 psi)    

Parking and Secondary Brake Valve

Parking brake release pressure at high idle ... 2580 ± 200 kPa (375 ± 29 psi)

Relief valve pressure setting for the parking and secondary brake valve ... 3170 ± 100 kPa (460 ± 15 psi)

Parking Brake Release Hydraulic Filter

Pressure setting for the bypass valve ... 379 kPa (55 psi)

Lockup Clutch and Solenoid Valve

Pressure Reduction Valve

Pilot pressure at low idle ... 1725 ± 70 kPa (250 ± 10 psi)

Table 5
Chart Of Shims For The Pressure Reduction Valve    
Pt. No. for the Shims     Thickness of the Shims     Change in Primary Pressure as a Result of One Shim    
5J-2721 Shim    
0.13 mm (0.005 inch)    

10 kPa (1.5 psi)    
6J-3993 Shim    
0.25 mm (0.01 inch)    

19 kPa (2.8 psi)    
5J-1036 Shim    
0.80 mm (0.031 inch)    

60 kPa (8.7 psi)    

Modulation Reduction Valve

Pressure at low idle ... 1720 ± 70 kPa (249 ± 10 psi)

Lockup clutch primary pressure at low idle ... 960 ± 35 kPa (139 ± 5 psi)

Table 6
Chart Of Shims For The Modulation Reduction Valve (1)    
Pt. No. for the Shims     Thickness of the Shims     Change in Primary Pressure as a Result of One Shim    
8J-4452 Shim    
0.12 mm (0.005 inch)    

10 kPa (1.4 psi)    
2S-0675 Spacer    
0.40 mm (0.016 inch)    

32 kPa (4.6 psi)    
9J-1330 Shim    
0.79 mm (0.031 inch)    

62 kPa (9.0 psi)    
( 1 ) Before an adjustment is performed, be certain that the valve springs are not weak or broken.

Table 7
Speed     Engaged Clutches     Torque Converter Drive     Direct Drive (Engaged Lockup Clutch)    
Neutral     1     X     -    
Reverse     3 and 7     X     -    
First Gear     2 and 6     X     X    
Second Gear     1 and 6     -     X    
Third Gear     3 and 6     -     X    
Fourth Gear     1 and 5     -     X    
Fifth Gear     3 and 5     -     X    
Sixth Gear     1 and 4     -     X    
Seventh Gear (2)     3 and 4     -     X    
( 2 ) This speed is not used on the 771D Quarry Trucks.

Transmission

Pressure Control Valve

Table 8
Station (1)     A     B     C     E     F     G     H    
Engaged Clutch     3     1     2     5     4     6     7    
Type of Test     Pressure    
Clutch Pressure At High Idle    
1700 + 240 - 100 kPa (247 + 35 - 15 psi)    

2035 + 240 - 100 kPa (295 + 35 - 15 psi)    

1885 + 240 - 100 kPa (273 + 35 - 15 psi)    

2015 + 240 - 100 kPa (292 + 35 - 15 psi)    

1430 + 240 - 100 kPa (207 + 35 - 15 psi)    

2930 + 240 - 100 kPa (425 + 35 - 15 psi)    

2930 + 240 - 100 kPa (425 + 35 - 15 psi)    
Primary Clutch Pressure At Low Idle    
520 + 50 - 35 kPa (75 + 7 - 5 psi)    

345 + 50 - 35 kPa (50 + 7 - 5 psi)    

380 + 50 - 35 kPa (55 + 7 - 5 psi)    

380 + 50 - 35 kPa (55 + 7 - 5 psi)    

380 + 50 - 35 kPa (55 + 7 - 5 psi)    

345 + 50 - 35 kPa (50 + 7 - 5 psi)    

345 + 50 - 35 kPa (50 + 7 - 5 psi)    
( 1 ) Station "D" is not used.

Table 9
Shims For The Pressure Control Valve
Pressure Change Per Shim    
Station (1)     A     B     C     E     F     G     H    
Engaged
Clutch    
3     1     2     5     4     6     7    
Thickness of Shim     Pressure Change     Pressure Change     Pressure Change     Pressure Change     Pressure Change     Pressure Change     Pressure Change    
5J-2721 Shim    

0.13 mm (0.005 inch)    

16 kPa (2.3 psi)    

14 kPa (2.0 psi)    

20 kPa (2.9 psi)    

17 kPa (2.5 psi)    

14 kPa (2.0 psi)    

17 kPa (2.5 psi)    

17 kPa (2.5 psi)    
6J-3993 Shim    

0.25 mm (0.010 inch)    

32 kPa (4.6 psi)    

28 kPa (4.1 psi)    

41 kPa (5.9 psi)    

35 kPa (5.1 psi)    

28 kPa (4.1 psi)    

33 kPa (4.8 psi)    

33 kPa (4.8 psi)    
4M-1751 Spacer    

0.41 mm (0.016 inch)    

50 kPa (7.3 psi)    

45 kPa (6.5 psi)    

65 kPa (9.4 psi)    

56 kPa (8.1 psi)    

45 kPa (6.5 psi)    

53 kPa (7.7 psi)    

53 kPa (7.7 psi)    
5J-1036 Shim    

0.80 mm (0.031 inch)    

98 kPa (14.2 psi)    

87 kPa (12.6 psi)    

125 kPa (18.2 psi)    

109 kPa (15.8 psi)    

87 kPa (12.6 psi)    

103 kPa (14.9 psi)    

103 kPa (14.9 psi)    
( 1 ) Station "D" is not used.

Table 10
Specifications And Identification Of The Components Of The Pressure Control Valve    
Location of the Load Piston Body (1)     A     B     C     E     F     G     H    
Thickness of the Load Piston Orifice    
4.58 mm (0.180 inch)    

2.54 mm (0.100 inch)    

4.58 mm (0.180 inch)    

4.58 mm (0.180 inch)    

2.54 inch (0.100 inch)    

4.58 mm (0.180 inch)    

4.58 mm (0.180 inch)    
Color of the Outer Spring of the Load Piston     Yellow color     Light blue color     Light green color     Light green color     Yellow color     Yellow color     Yellow color    
Color of the Inner Spring of the Load Piston     Light green color     Light green color     Light blue color     Orange color     Orange color     Light blue color     Light blue color    
Size of the Decay Orifice    
1.57 mm (0.062 inch)    

1.98 mm (0.078 inch)    

1.57 mm (0.062 inch)    

1.98 mm (0.078 inch)    

1.98 mm (0.078 inch)    

1.57 mm (0.062 inch)    
   
Color of the Decay Orifice     Green color     Red color     Green color     Red color     Red color     Green color        
( 1 ) The location of the load piston body is identical to the location of the station for the valve. Station "D" is not used.

Selector and Pressure Control Valve

Relief Valve

Relief valve setting ... 2790 ± 35 kPa (405 ± 5 psi)

Maximum pressure at high idle ... 3220 ± 110 kPa (467 ± 16 psi)

Table 11
Chart Of Spacers For The Relief Valve    
Pt. No. for the Spacers     Thickness of the Spacers     Change in Pressure as a Result of One Spacer    
145-0105 Spacer    
0.25 mm (0.010 inch)    

41 kPa (6.0 psi)    
145-0106 Spacer    
0.90 mm (0.035 inch)    

145 kPa (21.0 psi)    
145-0107 Spacer    
1.60 mm (0.063 inch)    

261 kPa (37.9 psi)    

Priority Reduction Valve

Setting of the pilot pressure for the priority reduction valve ... 1755 ± 35 kPa (255 ± 5 psi)

Table 12
Chart Of Spacers For The Priority Reduction Valve    
Pt. No. for the Spacers     Thickness of the Spacers     Change in Pressure as a Result of the Spacers    
5M-3492 Spacer    
0.25 mm (0.010 inch)    

17 kPa (2.5 psi)    
7M-1397 Spacer    
0.91 mm (0.036 inch)    

60 kPa (8.7 psi)    

Transmission Lubrication Pressure

Transmission lubrication pressure at high idle ... 172 to 276 kPa (25 to 40 psi)

Transmission lubrication pressure at low idle ... 17 to 70 kPa (2.5 to 10 psi)

Power Train Oil Filter

Pressure setting for the bypass valve ... 345 kPa (50 psi)

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