770 and 772 Off-Highway Trucks Power Train Transmission Hydraulic Control - Assemble Caterpillar


Transmission Hydraulic Control - Assemble
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1.1. Assembly Procedure

Assembly Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
1P-0510  Driver Group 
1U-5429  Retaining Ring Pliers 
9U-5839  Liquid Gasket 

  1. Check all of the O-ring seals and the components for wear or damage. Replace the components, if necessary.

  2. Lubricate all of the O-ring seals lightly with the lubricant that is being sealed.


    Illustration 1g00572566

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.


  3. Install body (89) and the O-ring seal into the selector and pressure control valve. Tighten body (89) to a torque of 85 ± 10 N·m (63 ± 7 lb ft).

  4. Install cap (93), spring (91), spacer (92), and valve (90) into the valve body. Tighten cap (93) to a torque of 85 ± 10 N·m (63 ± 7 lb ft).


    Illustration 2g00572564

  5. Install slug (86), spring (87), and ball (88) into spool assembly (82).

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.


  6. Use Tooling (B) (not shown) to install retaining ring (85) into spool assembly (82).


    Illustration 3g00572562

  7. Install spacers (83) into spool assembly (82).

  8. Install spring (84) and spool assembly (82) into the selector and pressure control valve. To determine the amount of shims that are required, refer to Testing and Adjusting, "Transmission Hydraulic Control Pilot Pressure - Test and Adjust".


    Illustration 4g00572559

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.


  9. If necessary, install dowels (80) into spring support assembly (79). The dowels (80) should protrude 6.5 ± 0.250 mm (0.26 ± 0.0098 inch) above the surface. Install support assembly (79), the hard washers, and bolts (81).


    Illustration 5g00572558

  10. Install pin (77) and pin (78) into rotary spool assembly (70). Use Holes (Y) as a reference to assemble pin (77). The pin (78) should be 0.8 ± 0.250 mm (0.0315 ± 0.0098 inch) below the surface.


    Illustration 6g01412372

  11. Install screen filter (73). Tighten screen filter (73) to a torque of 6.1 ± .7 N·m (54 ± 6 lb in). Position detent cam (74) into rotary spool assembly (70). Install spring pin (76) through rotary spool asssembly (70) and detent cam (74). Install spring pin (75) into spring pin (76) so that the slots that are in spring pin (75) are 180 ± 20 degrees from the slot that is in spring pin (76).


    Illustration 7g00574935

  12. Install rotary spool assembly (70) into the selector and pressure control valve. Install bolt (72) to a torque of 30 ± 7 N·m (22 ± 5 lb ft).

  13. Install spring assemblies (69), retainers (71), and two locating bolts (68). Tighten locating bolts (68) to a torque of 30 ± 7 N·m (22 ± 5 lb ft).

  14. Loosen bolts (81). Center the roller of spring assemblies (69) in the notches on rotary spool assembly (70). Tighten bolts (81) to a torque of 30 ± 7 N·m (22 ± 5 lb ft).


    Illustration 8g00572524

  15. Position the actuator body in a suitable press. Use Tooling (A) (not shown) to install roller bearing (67) into the actuator body. Roller bearing (67) should be 4.00 ± 0.50 mm (0.157 ± 0.0197 inch) above the surface.

  16. Install the spring pin and the exhaust valve assembly. The flat end of the exhaust valve assembly should be installed first. Install O-ring plug assemblies (65) and (66) into the actuator body.


    Illustration 9g01419158

  17. Install actuator vane (64) into the actuator body, as shown. Install bolts (63). Do not tighten bolts (63) at this time.


    Illustration 10g00572518

  18. Install actuator rotor assembly (62) into the actuator body.


    Illustration 11g01412397

  19. Position cover assembly (60) in a suitable press. Use Tooling (A) (not shown) to install roller bearing (61) into cover assembly (60). Roller bearing (61) should be recessed 7.20 ± 0.250 mm (0.283 ± 0.0098 inch) from the bottom of cover assembly (60).


    Illustration 12g00572490

  20. Install cover assembly (60) and bolts (59) to rotary actuator (58). Tighten bolts (59) to a torque of 30 ± 4 N·m (22 ± 3 lb ft). Tighten bolts (63) (not shown) to a torque of 13 ± 3 N·m (115 ± 27 lb in). The rotary actuator (58) must turn freely through 300 degrees of rotation.


    Illustration 13g00574568


    Illustration 14g00572487

  21. Position rotary actuator (58) into rotary spool assembly (70). The groove on rotary actuator (58) should line up with pin (78). Install bolts (57) and the hard washers. Tighten bolts (57) to a torque of 30 ± 4 N·m (22 ± 3 lb ft).


    Illustration 15g00572486

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.


  22. Install spring (53) and ball (54) into spool assembly (50). Install seat (55) and the O-ring seal into spool assembly (50).

  23. Use Tooling (B) to install retaining ring (56) into spool assembly (50).


    Illustration 16g00574313


    Illustration 17g00572482

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.


  24. Install O-ring seal (51) onto cover (52). Install spring (49), spool assembly (50), and cover (52) to the valve body. Tighten the bolts that hold cover (52) to a torque of 30 ± 7 N·m (22 ± 5 lb ft).


    Illustration 18g00572474

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.


  25. Install five spacers (41) into reducing spool assembly (42). Install retaining ring (40). In order to determine the amount of five shims (41) that are required, refer to Testing and Adjusting, "Transmission Hydraulic Control Pilot Pressure - Test and Adjust".

  26. Install check (43), spring (44), retainer (45), and retaining ring (46) into reducing spool assembly (42).

  27. Install reducing spool assembly (42) and spring (39) into the selector and pressure control valve. Install cover (47) and bolts (48). Tighten bolts (48) to a torque of 30 ± 7 N·m (22 ± 5 lb ft).


    Illustration 19g00572431

  28. Install load piston (36), hard washer (38), and bolt (37) to the valve body.


    Illustration 20g00572425

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.


  29. Install ball (32), spring (33) and retainer (34) into spool assembly (24).

  30. Use Tooling (B) in order to install retaining ring (35) into spool assembly (24).


    Illustration 21g00572601

    Note: The components in station (A) actuate clutch (3). The components in station (B) actuate clutch (1). The components in station (C) actuate clutch (2). The components in station (E) actuate clutch (5). The components in station (F) actuate clutch (4). The components in station (G) actuate clutch (6). The components in station (H) actuate clutch (7).



    Illustration 22g00572423

    ------ WARNING! ------

    Improper assembly of parts that are spring loaded can cause bodily injury.

    To prevent possible injury, follow the established assembly procedure and wear protective equipment.


    Note: Each load piston body is marked according to the clutch that is controlled. The valve body is marked by a letter at Location (X).


    NOTICE

    Failure to properly assemble parts or failure to follow established procedures can lead to damage of the parts and assembly.

    To avoid damage to parts, always identify and mark the parts so that they can be installed in the same location. Never force parts during assembly.


  31. Refer to Table 2 for installation purposes.

    Table 2
    Station  Thickness of Orifice (27)  Color of the Plug (30)  Inner Spring (17)  Outer Spring (18) 
    4.58 mm (0.180 inch)  Green  Green  Yellow 
    2.54 mm (0.100 inch)  Red  Green  Light Blue 
    4.58 mm (0.180 inch)  Green  Light Blue  Light Green 
    4.58 mm (0.180 inch)  Red  Orange  Light Green 
    2.54 mm (0.100 inch)  Red  Orange  Yellow 
    4.58 mm (0.180 inch)  Green  Light Blue  Yellow 
    4.58 mm (0.180 inch)    Light Blue  Yellow 

  32. Install slug (23) into spool assembly (24).

  33. Install spring (16), spool assembly (24), and stop (25) into the valve body.

  34. Install plugs (30), O-ring seal (28), cascade orifice (27), and spring (26) into load piston body (29).

    Note: Valve Group (H) has two plugs (30).

  35. Install load piston (21), selector piston (22), spacer (20), shims (19) and two springs (17) and (18) into load piston body (29). To determine the amount of shims (19) that are required, refer to Testing and Adjusting, "Transmission Hydraulic Control Pilot Pressure - Test and Adjust".

  36. Position load piston body (29) onto the valve body. Install socket head bolts (31) and the washers.

  37. Repeat Steps 31 through 36 for the remaining six stations.


    Illustration 23g00572421

  38. Install O-ring plugs (15) and the O-ring seals into valve body (14).


    Illustration 24g00572418

  39. Position manifold assembly (2) in a suitable press. Use Tooling (A) (not shown) to install bearing (13) into manifold assembly (2). Bearing (13) should be recessed 0.5 mm (0.02 inch) below the surface.


    Illustration 25g00572417

  40. Install lip seal (12) into manifold assembly (2). ApplyTooling (C) to the bore of manifold assembly (2). Allow the Liquid Gasket to become tacky before installing lip seal (12). Lubricate the lip of lip seal (12) lightly with the lubricant that is being sealed.


    Illustration 26g00572416

  41. Install harness assembly (10), cover (11), bolts (9), and the washers to manifold assembly (2).


    Illustration 27g00572413

  42. Install backup rings (8) and O-ring seals (7) onto each of the cartridge assemblies.


    Illustration 28g00572408

  43. Install cartridge assemblies (6) into the manifold assembly. Tighten cartridge assemblies (6) to a torque of 50 ± 5 N·m (37 ± 4 lb ft).


    Illustration 29g00572402

  44. Install plug (5) and the O-ring seal to the manifold assembly.

  45. Install coil assemblies (3) onto the cartridge assemblies. Install locknuts (4). Tighten locknuts (4) to a torque of 9 ± .5 N·m (80 ± 4 lb in).

  46. Install O-ring seals (1) to manifold assembly (2).

End By:

  1. Install the transmission hydraulic control. Refer to Disassembly and Assembly, "Transmission Hydraulic Control - Install".

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