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Bienvenido: cr120jvxr
Producto: TRUCK
Modelo: 785D TRUCK MSY
Configuración: 785D OffHighway Truck MSY00001UP (MACHINE)
POWERED BY 3512C Engine
Pruebas y Ajustes
785D OffHighway Truck Power Train
Número de medio KENR830703 Fecha de publicación 01/03/2012 Fecha de actualización 14/03/2012
i01250670
Transmission Troubleshooting
SMCS 3030
Personal injury or death can result from sudden machine movement.
Sudden movement of the machine or release of air pressure or oil
pressure can cause injury to persons on or near the machine.
To help prevent possible injury before testing and adjusting any air
system or hydraulic system, perform the procedure in the Testing and
Adjusting, "General Information" section.
Before troubleshooting a problem, perform the visual checks. Perform the checks with the engine OFF
and with the parking brakes ON. Put the transmission control in NEUTRAL and the transmission rotary
selector spool in NEUTRAL1. During the checks, use a magnet to separate ferrous particles from
nonferrous particles.
Check: Check the oil level in the transmission section of the
hydraulic tank.
Check the oil level in the transmission section of the hydraulic tank. Look for air or for water at the sight
gauge. Many problems in the transmission are caused by low oil levels or by air in the oil. if necessary,
add oil to the transmission section of the hydraulic tank. In order to determine the correct oil to use,
refer to your Operation and Maintenance Manual.
Problem: The oil level is too high.
Probable Cause
Oil is leaking from the pump drive into the transmission gear pump.
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21/12/2014 785D OffHighway Truck MSY00001UP (MACHINE) POWERED BY 3512C Engine(SEBP4998 44) Sistemas y componentes
The oil from the differential and bevel gear leaks into the transmission case. One potential reason
for the leaks is the failure of the pinion seal in the differential. The leaks can also occur if the
center plug of the differential pinion is not installed or if the center plug does not fit properly.
Problem: There is an indication of water in the oil.
Probable Cause
Illustration 1 g00666175
(1) Transmission oil cooler
Failure of transmission oil cooler (1)
Problem: There is an indication of air in the oil.
Probable Cause
Perform "Check for oil leakage".
Problem: The oil level is too low.
Probable Cause
Perform "Check for oil leakage". Add oil before any tests are performed.
Check: Check for oil leakage.
Inspect all the oil lines, the hoses, and the connections for damage or for leaks. Look for oil on the
ground under the machine.
Note: If oil can leak out of a fitting or a connection, air can enter the system. Air in the system can be as
harmful as not enough oil.
Check: Check the transmission charging hydraulic filter.
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Illustration 2 g00666185
(2) Transmission charging hydraulic filter
Remove transmission charging hydraulic filter (2). Inspect the filter for foreign material.
Note: Transmission charging hydraulic filter (2) has an oil filter bypass valve. An oil filter bypass valve
allows oil to bypass the oil filter element whenever the pressure difference between the inlet oil and the
outlet oil at the oil filter gets too high. Any oil that does not go through the filter element flows directly
into the hydraulic circuit. Dirty oil causes restrictions in valve orifices and in sticking valves.
The difference of the pressure setting at the bypass valve in transmission charging hydraulic filter (2) is
approximately 250 kPa (36 psi).
Problem: Rubber particles are found.
Probable Cause
Seal failure
Hose failure
Problem: Shiny steel particles are found.
Probable Cause
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Illustration 3 g00367714
Transmission gear pump
(3) Transmission scavenge pump section
(4) Transmission lubrication section of the pump
(5) Transmission charging pump section
Mechanical failure of transmission charging pump section (5)
Check: Check the transmission magnetic screens.
Illustration 4 g00290397
Lower right side of the transmission case
(8) Magnetic screens
Remove magnetic screens (8). Inspect magnetic screens (8) for foreign material and/or for restrictions.
Problem: Rubber particles are found.
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21/12/2014 785D OffHighway Truck MSY00001UP (MACHINE) POWERED BY 3512C Engine(SEBP4998 44) Sistemas y componentes
Probable Cause
Seal failure
Hose failure
Problem: Black coarse material is found.
Probable Cause
Worn clutches in the transmission
Failure of a thrust disc
Problem: Thin strands that are elastic are found.
Probable Cause
Worn clutches in the transmission
Problem: Iron chips or steel chips are found.
Probable Cause
Broken components in the transfer gears or in the transmission
Problem: Aluminum particles are found.
Probable Cause
Worn housings, load pistons, or selector pistons in the pressure control valve
Check: Check the parts inside the transmission case.
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Illustration 5 g00290399
(10) Transmission drain plugs
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Remove plugs (10) in the bottom of the transmission case. This will drain all the oil out of the
transmission and the transfer gears. Measure the total amount of the oil that is removed at both plugs.
Inspect the oil for foreign material.
Problem: More than 76 L (20 US gal) of oil are drained from the transmission and
the transfer gears.
Probable Cause
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21/12/2014 785D OffHighway Truck MSY00001UP (MACHINE) POWERED BY 3512C Engine(SEBP4998 44) Sistemas y componentes
Illustration 6 g00290397
Lower right side of the transmission case
(8) Magnetic screens inside the case
Restriction in magnetic screens (8)
Failure of the transmission scavenge pump section
Too much leakage in a clutch of the transmission
Problem: Rubber particles are found.
Probable Cause
Seal failure
Problem: Black coarse material is found.
Probable Cause
Worn clutches in the transmission
Failure of a thrust disc
Problem: Thin strands that are elastic are found.
Probable Cause
Worn clutches in the transmission
Problem: Iron chips or steel chips are found.
Probable Cause
Broken components in the transfer gears or in the transmission
Problem: Aluminum particles are found.
Probable Cause
Worn housings, worn load pistons, or worn selector pistons in the pressure control valve
Check: Check the parts inside the transmission section of the
hydraulic tank.
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21/12/2014 785D OffHighway Truck MSY00001UP (MACHINE) POWERED BY 3512C Engine(SEBP4998 44) Sistemas y componentes
Illustration 7 g00367725
(11) Transmission section of the hydraulic tank
Illustration 8 g00373873
(12) Suction screen
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
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21/12/2014 785D OffHighway Truck MSY00001UP (MACHINE) POWERED BY 3512C Engine(SEBP4998 44) Sistemas y componentes
Drain the oil from the transmission section of the hydraulic tank (11). Inspect the bottom of the oil tank
for debris. Remove the suction screen (12) for the transmission gear pump. Clean the suction screen (12)
.
Problem: Rubber particles are found.
Probable Cause
Seal failure
Hose failure
Problem: Shiny steel particles are found.
Probable Cause
Illustration 9 g00367714
Transmission gear pump
(3) Transmission scavenge pump section
(4) Transmission lubrication section of the oil pump
(5) Transmission charging pump section
There is a mechanical failure of the transmission scavenge pump section (3) .
Problem: Black coarse material is found.
Probable Cause
Worn clutches in the transmission
Failure of a thrust disc
Problem: Thin strands that are elastic are found.
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21/12/2014 785D OffHighway Truck MSY00001UP (MACHINE) POWERED BY 3512C Engine(SEBP4998 44) Sistemas y componentes
Probable Cause
Worn clutches in the transmission
Problem: Aluminum particles are found.
Probable Cause
Worn housings, worn load pistons, or worn selector pistons in the pressure control valve
Note: If any of the particles that are listed in the checks are found during a visual check, all the
components of the transmission systems must be cleaned. Do not use any damaged parts. Damaged parts
must be removed and new parts must be installed.
Copyright 1993 2014 Caterpillar Inc.
Todos los derechos reservados.
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