Tren de Fuerza 793C
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Transcript of Tren de Fuerza 793C
Entrenamiento de Servicio MATERIAL PARA Programa de Certificación EL ESTUDIANTE
Camiones Grandes de Obras Modulo III
Power Train
Nombre del Participante: _____________________________________________________________
Camión a ser certificado: ______________________________________________________________
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NOTAS DEL PARTICIPANTE
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DESCRICION DEL MODULO OBJETIVOS
DURATION PRE REQUISITES
POWER TRAIN
In this module, you will find a set of sheets titled “Module III – Preparation for Skill Check”. After to study this subject and answer 100% of the questions the participant will be able to perform the “Module III Skill Check Worksheet”.
The participant can use all service literatures available in this room to study and work on each module. The facilitator will be available to provide the necessary guidance about the student’s material. This self study will be conducted according participant’s choice.
The OHT Power Train module covers the torque converter, transmission hydraulic and electronic systems, rear axle and final drives. Note: Consider that the operation in direct drive of the ICM transmission hydraulic control for 793C is unique in comparison to any other Off-Highway Truck.
OBJETIVOS DEL MODULO
1. Given a “Module III - Preparation for Skill Check sheet – Power Train Hydraulic Circuits”, fill the written questionnaire and submit it to the facilitator’s approval. The service literature’s search is allowed.
2. Given a “Module III – Skill check worksheet – components identification”, choose the necessary tools and service procedures and go to the machine to perform them. The service literature’s search is allowed.
3. Given a “Module III – Skill check worksheet – Power train calibrations”, choose the necessary tools and service procedures and go to the machine to perform it. The service literature’s search is allowed.
4. Given a “Module III – Skill check worksheet – Power train pressure test”, choose the necessary tools and service procedures and go to the machine to perform it. The service literature’s search is allowed.
02:30 h
Be able to search on SIS CD or SIS Web English technical instructions comprehension Use of ET Caterpillar Electrical Schematic interpretation Previous experience supporting Large OHT
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Preparación Para las Tareas: Modulo III – Power Train Plan de acción para las tareas – Por favor revise con cuidado las necesidades de su practica y asegúrese que reúne todo antes de empezar las tareas del modulo. Son seis partes que debe completar antes de ir a la maquina
• 1. Cuestionario – Es una serie de preguntas que debera contestar, en algunos casos debera buscar la respuesta todo dependera de sus conocimientos.
• 2. Listado de tareas – Estas son las tareas que debera cumplir para completar este modulo, normalmente se trata de por lo menos una hoja de trabajo con sus instruccciones por cada tarea:
a. Localizacion de componentes del sistema del modulo III.
b. Calibraciones y estrategia del sistema del modulo III.
c. Prueba de presiones del sistema del modulo III.
Nota el ejercicio del ET se puede practicar en el computador antes de ir a la maquina con el ET trainer
• 3. Escoger las herramientas y materiales – En la hoja de materiales y herramientas que recibio en la introduccion, decida que se necesitara para el cumplimiento de cada tarea.
• 4. Conseguir los procedimientos para las tareas – Para realizar la tarea debe seguir una serie de pasos, que normalmete estan en el manual de servicio, debe localizar el procedimiento (copia del libro o impresión del SIS).
• 5. Registrar las especificaciones – Cada tarea tiene una hoja de registro de datos, escriba las especificaciones de acuerdo al manual de servicio donde sea necesario.
• 6. Recibir la aprobacion del facilitador para la realizacion de la tarea – Una vez que cumpilo con todos los requerimientos en la preparacion para las tareas, puede pasar a donde el facilitador para conseguir su aprobacion
Nombre del facilitador: ____________________________ Firma ____________
Hora Inicio: ___________ Fecha __________ Hora Fin: ___________ Fecha __________
Es tiempo de ir a la maquina
Coloque unamarca de
aprobación en el cuadro
cuando termine
cada parte
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Large Off-Highway Trucks
Module III – Preparation for skill check
Objetivo 1: Power Train Hydraulic Circuits
1) Media number for 785C Power Train Systems Operation _______________________________
2) Fill the blank with the correct number from TC lockup clutch control schematic:
_____ oil from parking brake release system
_____ oil to transmission lube
_____ oil from transmission charging pump
_____ oil to lockup clutch
_____ oil to station “D”
_____ pilot pressure to the lockup modulation valve
1A
2A
3A
4A
5A
6A
785/789C
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Large Off-Highway Trucks Module III – Preparation for skill check
Description: Power Train Hydraulic Circuits
3) Fill the blank with the correct number from TC and transmission hydraulic system
_____ TC charging oil filter _____ Rear brake oil coolers
_____ Front brake oil cooler _____ TC charging section
_____ Converter scavenge section _____ Parking brake filter
_____ Parking brake retraction valve _____ Diverter valve
_____ Converter outlet screen _____ Rear brake cooling pump (789)
_____ Parking brake release pump _____ Oil to transmission lube
9A
10A
7A
6A
3A
2A
1A
5A
4A
11A 8A
12A
785/789C
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4) On the schematic above, use arrows (→) to trace the correct oil flow to the following circuits:
_____ Transmission charging circuit
_____ Transmission oil cooling and lube circuit
_____ TC lockup relay and modulation valve
Large Off-Highway Trucks Module III – Preparation for skill check
Description: Power Train Hydraulic Circuits
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1
2
3
4
5
6
5) Media number for 793C Power Train Systems Operation _______________________________
6) Fill the blank with the correct number from TC lockup clutch control schematic: _____ oil from transmission charging pump
_____ oil to transmission lube pump
_____ oil from transmission charging pump
_____ oil to lockup clutch
_____ oil to station “D”
_____ pilot pressure to the lockup modulation valve
793C
Large Off-Highway Trucks Module III – Preparation for skill check
Description: Power Train Hydraulic Circuits
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7 8
910
15
11
13
12
14
16
793C
Large Off-Highway Trucks Module III – Preparation for skill check
Description: Power Train Hydraulic Circuits
7) Fill the blank with the correct number from TC and transmission hydraulic system
_____ TC charging oil filter
_____ TC outlet orifice and screen
_____ Transmission lubrication section
_____ TC/transmission cooler
_____ Transmission charging section
_____ TC charging section
_____ Up shift solenoid
_____ Downshift solenoid
_____ Lockup solenoid
_____ Transmission scavenge section
_____ TC lockup valve
17
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Large Off-Highway Trucks Module III – Preparation for skill check
Description: Power Train Hydraulic Circuits
8) On the schematic above, use arrows (→) to trace the correct oil flow to the following circuits:
_____ Transmission charging circuit
_____ TC charging circuit
_____ Transmission oil cooling circuit
_____ Transmission oil lube circuit
793C
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9) Fill the blank with the correct number from Transmission ICM Hydraulic System (785/789C)
Large Off-Highway Trucks Module III – Preparation for skill check
Description: Power Train Hydraulic Circuits
33A
____ Selector valve group
____ Charging pump
____ Lube pump
____ Pump pressure tap
____ Pilot oil pressure tap
____ Lockup solenoid
____ Downshift solenoid
____ Upshift solenoid
____ Upshift pressure tap
____ Downshift pressure tap
____ Priority reduction valve
____ Neutralizer valve
____ Rotary selector spool
____ Dual stage relief valve
____ Lubrication relief valve
____ Filters
____ Pressure control group
____ Cooler bypass valve
785/78931A
21A 24A
20A
32A
22A18A
30A
29A
35A
19A 23A
26A
25A
28A 27A
34A
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10) Fill the blank with the correct number from Transmission ICM Hydraulic System
33
____ Selector valve group
____ Charging pump
____ Lube pump
____ Pump pressure tap
____ Pilot oil pressure tap
____ Lockup solenoid
____ Downshift solenoid
____ Upshift solenoid
____ Upshift pressure tap
____ Downshift pressure tap
____ Priority reduction valve
____ Neutralizer valve
____ Rotary selector spool
____ Dual stage relief valve
____ Lubrication relief valve
____ Clutch supply pressure
____ Pressure control group
34
793C
19
18
20
21
22
23
24
26
27 29
25
28
31 30
32
Large Off-Highway Trucks Module III – Preparation for skill check
Description: Power Train Hydraulic Circuits
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11) Fill the blank with the correct number from Valve Station
_____ Drain
_____ Clutch supply rail (pressure)
_____ Oil pressure to clutch
_____ Clutch pressure tap
_____ Decay orifice
_____ Load piston orifice
_____ Load piston plug
_____ Selector piston
_____ Load piston
_____ Modulation reduction valve
Large Off-Highway Trucks Module III – Preparation for skill check
Description: Power Train Hydraulic Circuits
36
37 38
45 44
43
42
41
40
39
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Large Off-Highway Trucks Module III – Preparation for skill check
Description: Power Train Hydraulic Circuits
12) Explain the function of:
Priming bleed orifice (793C) - __________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Lock up reducing valve (all trucks) - _____________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Transmission pressure control valve (all trucks) - ___________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Priority reduction valve (793C) - _______________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Priority reduction valve (785/789C) - ____________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Neutralizer valve (all trucks) - __________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Cooler bypass valve (785/789) - ________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
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Large Off-Highway Trucks Module III – Preparation for skill check
Description: Power Train Hydraulic Circuits
REAR AXLE FILTER SYSTEM
1
2
3
4
5 6
13) Fill the blank with the correct number from rear axle filtering system schematic:
_____ Flow control valve
_____ Oil filter
_____ Differential oil pump
_____ Rear axle
_____ Suction screen
_____ Temperature / pressure control valve
14) On the schematic above, use arrows (→) to trace the correct oil flow on rear axle filtering system at
temperatures below 43° C (110° F). Done
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Large Off-Highway Trucks Module III – Preparation for skill check
Description: Power Train Hydraulic Circuits
15) The Transmission Chassis ECM controls the following functions: hoist system rear axle cooling automatic lubrication grease neutral start function back up alarm throttle back up.
16) Fill with “x” all characteristics related to each component. Note: each component can have more than one characteristic
COMPONENT INPUT OUTPUT ANALOG SIGNAL
DIGITAL SIGNAL
FREQUENCY SIGNAL
SOLENOID ON / OFF
Transmission output speed sensor Body position sensor
Engine output speed sensor Transmission oil temperature sensor
Torque converter oil temp sensor Hoist raise solenoid Downshift solenoid Auto lube solenoid
Starter relay
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17) Write the meaning of the following messages from transmission ECM events:
Message Meaning
Shift counter
Lock up counter
Coasting in Neutral Counter
Transmission Abuse
Engine Overspeed
Machine Overspeed
18) Use the numbers from 1 to 6 to fill the blanks to define the actions priority the technician should follow during any power train hydraulic pressure test: ____ Write a list of necessary tools to perform the test ____ Have the correct test procedure in your hands before to perform it ____ Check if the oil is at operating temperature ____ Check if the filters and screens are clean ____ Write the machine model, serial number, hour meter, component s/n, before to start the test ____ Choose the correct literature media number.
Large Off-Highway Trucks Module III – Preparation for skill check
Description: Power train
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19) Use the numbers from 1 to 6 to fill the blanks to define the actions priority during the procedure to check the clutch control valve (station) primary pressure. (initial pressure). ____ Record the pressure and compare with the service manual table ____ Remove the load piston plug off, at the related clutch ____ Check if the transmission test cover _______________ is installed ____ Remove the drive axles from the machine or disconnect the drive shaft from T.C. ____ Manually engage the shift related to the clutch control valve to be checked ____ Install the ________________ gauge at the related clutch control valve (station)
20) Write 3 conditions that can cause the following: Problem: The pressure in one clutch at high idle is not correct but the primary pressure in the same clutch is correct.
1 - ______________________________________________________________________________
2 - ______________________________________________________________________________
3 - ______________________________________________________________________________
21) Write the following part numbers for the parts assembled inside the clutch control valve 5 (station F)
Part number Name
________________ Spring inner
________________ Spring outer
________________ Plug orifice (decay orifice)
22) By consulting the Service Manual module or SIS Web, fill the “Module III Skill Check Worksheet – Power Train Pressure Test” (attached), with the specifications necessary to perform the test: print a copy of the procedure from SIS and follow it.
Done
Large Off-Highway Trucks Module III – Preparation for skill check
Description: Power train
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MAQUINAS
HERRAMIENTAS
Maquinas Requeridas 1-Camión
Herramientas Requeridas ______ 1 Lap-top computer with ET v3.2 and VIMSpc99 v.2.0.3. ______ 1 7X1701 Communications Adapter with SPM NEXG4523
installed in ______ 1 7X1425 cable (lap-top to CA) ______ 1 1394166 Universal Data Link Cable or ______ 1 1714400 Communication Adapter II Group ______ 1 1960055 Cable ______ 1 VIMS Simulator (OHT configuration) ______ 1 7X1695 timing probe cable ______ 1 6V2197 timing probe magnetic pickup ______ 1 6V3093 timing probe adapter sleeve ______ 1 1279797 cable (lap-top to VIMS download port) ______ 1 8T5200 signal generator ______ 1 7X6370 cable 3-pin DT connector breakout Tee ______ 1 9U7330 Fluke 87 (28-16) ______ 1 7X1710 probe group ______ 1 1U5481 pressure gauge group ______ 1 1U5482 pressure adapter group ______ 1 6V6064 transm. test cover assy. ______ 1 4C4892 fitting gp (32-54)** or ______ 1 7X0871 Tee/1 6V8398 o-ring seal/1 6V3965 nipple assy/
1 3J1907 o-ring seal ______ 1 6V7830 tetra gauge ______ 1 4C4890 hydraulic test gp ______ 1 6V4157 test group ______ 1 6V9509 face seal plug ______ 1 6V9511 face seal plug ______ 1 6V9830 cap assy ______ 1 6V9831 cap assy ______ 1 6V3935 nipple (to read the front brk cooling system press
at hoist valve 793C)
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______ 1-Cronometro (Stop Watch) ______ 1 infrared thermometer ______ 1 mechanical tool box (including 9S1721 extension
1/4"square drive, 9U6635 reversible ratchet, 5P3277 tape measure, 5P3920 rule, vernier caliper, Hex key wrench mm and inch (3/8" steering cutout/cut-in)
______ 1-5P 3277 Cinta Métrica (Tape Measure) ______ 1-Scale de 150mm ______ 1 8T0853 pressure gauge ( 85 psi) ______ 2 8T0854 " " ( 145 psi) ______ 2 8T0859 " " (3600 psi) ______ 2 8T0860 " " (5800 psi)
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MATERIAL DEL ESTUDIANTE
MATERIAL DEL ESTUDIANTE
Descripción Form No.Camión de Obras 793C
Specification 793C 3500B/3500B High Displacement SENR1122 Specification 793C OHT Power Train SENR1448 Specification 793C OHT Steering System SENR1451 Specification 793C Hydraulic System SENR1457 Specification 793C Air System and Brakes SENR1453 Spec, S.O., T & A 793C Traction Control System SENR2986 Systems Operation 793C Automatic Lube System SENR4724 Systems Operation Exhaust by pass 793/B/C OHT SENR5092 Systems Operation 3500/B High Disp. Engines SENR1123 Systems Operation 793C Power Train Elec Control SENR1502 Systems Operation 785/797 VIMS Payload Mon… RENR2625 Systems Operation 793C Air System and Brakes SENR1592 Systems Operation 793C Hydraulic System SENR1504 Systems Operation 793C Power Train RENR2675 Systems Operation 793C Steering System RENR1452 OHT Vital Information Management System (VIMS) RENR2630____ Vital Information Management System (VIMS) SENR6059 T & A, Troubleshooting VIMS RENR2631 793 Power Train Testing & Adjusting SENR1450 Systems Operation 793C OHT Road Analysis Control RENR2636 793C OHT Electrical System (pub date 2000/08/01) RENR2642 793C OHT Electrical System (pub date 1998/10/01) SENR1541 793C OHT Hydraulic Schematic SENR1564 793C Specalog AEHQ5186 793C Operation & Maintenance Manual SEBU7175 Machine Fluids Recommendations SEBU6250
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MATERIAL DE ENTRENAMIENTO
Videos _____ 793C OHT Service Introduction SEVN4016 _____ 3500 Engines EUI Service Introduction SEVN2241
CDs _____ 3500B MEUI Fuel System RENR1395 _____ CAT C Series Mining Trucks YERA3501
Libros de Referencia _____ Operation & Maintenance Manual SEBU7175 _____ Service Manual SENR1540 _____ Parts Book SEBP2791
Material de entrenamiento _____ 793C Off-Highway Trucks SESV1682 _____ 3500B Engine Controls (EUI) SESV1681
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Large Off-Highway Trucks
Module III – Skill Check Worksheet
Objective 2: Components Identification (large OHT)
Go to the machine and perform the “Skill Check Worksheet”. The facilitator will observe you during the activity. When you finish the activity ask him to sign off this “Skill Check Worksheet”.
1) Go around the machine and identify the following components and/or pressure check points related
to power train system:
_____ Lockup modulation valve
_____ T.C outlet relief valve, pressure check point
_____ T.C. oil temperature sensor
_____ T.C. inlet relief valve, pressure check point
_____ Lockup reducing valve
_____ Lockup pressure check point
_____ T.C. charging pump
_____ Transmission lube pressure checkpoint
_____ Transmission charging pressure pump, checkpoint
_____ Transmission hydraulic control pilot pressure, check point
_____ Lock up solenoid
_____ Downshift solenoid
_____ Transmission magnetic screen
_____ Transmission output speed sensor
_____ Rear axle temperature/pressure control valve
_____ Differential thrust pin
_____ Service/retarder brake switch
Nombre del facilitador: _______________________________________ Firma _______________
Hora Inicio: ____________ Fecha _______________
Hora Fin: ____________ Fecha _______________
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Large Off-Highway Trucks
Module III – Skill Check Worksheet
Objective 3: Power Train Calibrations (large OHT) Choose the literature and tools necessary to perform this activity. Go to the machine and perform the “Skill Check Worksheet”. The facilitator will observe you during the activity. When you finish the activity ask him to sign off this “Skill Check Worksheet”.
1) Take a laptop with ET installed, go to the machine, communicate with the transmission ECM:
- Print to file the transmission/chassis configuration. Create a new file title “793C Tinaja” and
type the description “Transmission/chassis ECM”
2) Do the following calibrations: - Transmission gear limit - 4
- Body up gear limit - 3
- Print the new configuration to the same file and description “New config”.
Nombre del facilitador: _______________________________________ Firma _______________
Hora Inicio: ____________ Fecha _______________
Hora Fin: ____________ Fecha _______________
Literature Form
Tools, accessories
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Module III – Skill Check Worksheet
Objective 4: Power Train pressure test
Choose the necessary tools, service procedures and write the desired value cells before to go
to the machine.
TORQUE CONVERTER PRESSURE TESTS
Machine Serial No. ___________________________Machine Hours: ________________________
Transmission Serial No: _______________________Transmission Hours: _____________________
VISUAL CHEKS
Oil Level: __________________________________Oil Viscosity: __________________________
Air/Water in Oil? _____________________ Oil Filter Examination: ___________________
1) TORQUE CONVERTER OUTLET RELIEF VALVE PRESSURE (Large OHT)
Tool List:
Specification Actual
Oil temperature
Transmission gear
Engine rpm
Read the pressure at tap _______
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Tool List:
Specification Actual
Oil temperature
Transmission gear
Engine rpm
Parking brake
2) TORQUE CONVERTER LOCKUP CLUTCH PILOT PRESSURE (Large OHT)
Read pressure tap
_______
Oil temperature
Transmission gear
1) Engine rpm:
2)
Parking brake
Additional instruction
1)
3) TORQUE CONVERTER LOCKUP CLUTCH SIGNAL PRESSURE (Large OHT)
Read the pressure at tap
_______ 2)
Large Off-Highway Trucks Module III – Skill check worksheet
Objective 4: Power train pressure test
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Tool List:
Specification Actual
Oil temperature
Transmission gear
Engine rpm:
Parking brake
Additional instruction
4) TORQUE CONVERTER LOCKUP CLUTCH MAXIMUM PRESSURE (Large OHT)
Read the pressure at tap
Oil temperature
Transmission gear
Engine rpm:
Parking brake
Additional instruction
5) TORQUE CONVERTER LOCKUP CLUTCH PRIMARY PRESSURE (Large OHT)
Read the pressure at tap
Large Off-Highway Trucks Module III – Skill check worksheet
Objective 4: Power train pressure test
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LOCKUP SOLENOID DE-ENERGIZED 785/789C
Specification Actual
LI HI LI HI
6) PUMP PRESSURE (minimum)
(maximum)
Transmission oil temperature during tests
7) LUBE PRESSURE
8) Write what clutches are engaged for each transmission speed (Large OHT)
TRANSMISSION SPEED
ENGAGED CLUTCHES
TRANSMISSION SPEED
ENGAGED CLUTCHES
TRANSMISSION SPEED
ENGAGED CLUTCHES
NEUTRAL 1 THIRD speed REVERSE
NEUTRAL 2 FOURTH speed
FIRST speed FIFTH speed
SECOND speed SIXT speed
(Large OHT) 9) MAXIMUM CLUTCH PRESSURE (Large OHT) Load piston plug installed. Lockup sol disconnected
STATION CLUTCH Specification Actual
LI HI LI* HI*
B 1 C 3 F 5 G 6
Large Off-Highway Trucks Module III – Skill check worksheet
Objective 4: Power train pressure test
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10) Check the transmission pump pressure adjust versus transmission clutch supply rail when the 793C is operating both in torque converter and direct drive
DUAL STAGE RELIEF LOCKUP SOLENOID DE-ENERGIZED SPECS ACTUAL LI HI LI HI
PUMP PRESSURE (AA - at pressure tap L)
(Transmission Neutral)
Transmission oil temperature during tests
DUAL STAGE RELIEF LOCKUP SOLENOID ENERGIZED
SPECS ACTUAL
LI 1300 RPM LI 1300 RPM
PUMP PRESSURE (EE) (at station C)
xxxxxxxxx
xxxxxxxxx
PUMP PRESSURE (DD) (at pressure tap L)
xxxxxxxxx xxxxxxxxx
LUBE PRESSURE (see manual) 5 TO 65 kPa (.5 to 10 psi)
160 ± 50 kPa (23 ± 7 psi)
Nombre del facilitador: _______________________________________ Firma _______________
Hora Inicio: ____________ Fecha _______________
Hora Fin: ____________ Fecha _______________
793C ONLY
Large Off-Highway Trucks Module III – Skill check worksheet
Objective 4: Power train pressure test
NOTE: priority reducing valve is used to set pressure (DD) in direct drive only. Setting pressure (DD) in direct drive to 2310±70 kPa (335±10psi) will cause the pilot pressure (BB) to be approximately 2400 to 2750kPa (350 to 400 psi) when the machine is in torque converter drive.
Do not shim transmission priority reducing valve in order to control pilot pressure. The pilot pressure is a result of setting the pressure of the transmission charging pump section when the machine is in direct drive.