Bench Test Procedure For A 768C, 769C, 772B, and 773B Off-Highway Truck Torque Converter{3101, 3133} Caterpillar

Off-Highway Truck/Tractor:

768C (S/N: 02X1-UP)

769C (S/N: 01X1-UP)

772B (S/N: 64W1-UP)

773B (S/N: 63W1-UP)

Introduction

© 2011 Caterpillar All Rights Reserved. This guideline 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.

This special instruction contains the necessary information that is required to bench test a specific torque converter arrangement. Refer to Table 2 for the correct arrangements. Bench testing the torque converter ensures correct assembly and operation of the component. Testing a torque converter provides the most conclusive evaluation. Testing allows the dealer to ensure that the torque converter will operate properly in the machine. The specifications in this guideline are specific to bench testing the component. Every effort has been made in order 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 guideline must be used with the latest technical information that is available from Caterpillar.

For questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. In order to address an urgent issue, use the following resources in order to communicate your request to Caterpillar Repair Process Engineering:

• Caterpillar Dealer Technical Communicator

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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.

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 in order 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

Note: Pressures will be sensitive to tooling setup. The diameter of the hose, the diameter of a fitting, and additional filtering can affect pressure. The required tools that are listed in Table 3 were used in order to develop this test procedure.

Installation Procedure

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Illustration 1	g01291578

1. Install Tooling (A) .

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Illustration 2	g01291582

2. Install Tooling (B) onto Tooling (A) .

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Illustration 3	g01291592

3. Install Tooling (C) .

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Illustration 4	g01291565

4. Install Tooling (D) .

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Illustration 5	g01291566

5. Remove pump (1) .

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Illustration 6	g01291587

6. Install Tooling (E) to the torque converter.

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Illustration 7	g01291607

7. Use a hoist to install the torque converter on the test bench. The weight of the torque converter is 298.5 kg (658 lb).

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Illustration 8	g01291608

8. Use Tooling (F) in order to secure the torque converter to Tooling (B) .

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Illustration 9	g01291616

9. Tighten the collet on Tooling (C) in order to connect Tooling (C) to Tooling (E) .

   Note: Refer to Special Instruction, SEHS8763, "Assembly and Operation of 1U-5999 Spindle Group Used for Testing Transmissions on Hydraulic Test Bench" for additional information.

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Illustration 10	g01291622

10. Install Tooling (G) .

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Illustration 11	g01291642

11. Install Tooling (H) .

    Note: Tooling (H) will adapt to the small drive shaft. If the large drive shaft is being used, install Tooling (J) on Tooling (H) .

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Illustration 12	g01291645

12. Align the torque converter with the input drive shaft.

13. Connect the input drive shaft to Tooling (H) .

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Illustration 13	g01291648

14. Install the drive shaft guard.

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Illustration 14	g01291655

15. Remove magnetic filter (2) .

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Illustration 15	g01291672

16. Install Tooling (K) .

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Illustration 16	g01291661

17. Remove cover (3) .

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Illustration 17	g01291666

18. Install Tooling (L) .

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Illustration 18	g01291681

19. Remove plug (4) .

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Illustration 19	g01291685

20. Install Tooling (M) .

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Illustration 20	g01291686

21. Remove plug (5) .

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Illustration 21	g01291688

22. Install Tooling (N) .

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Illustration 22	g01291694

23. Remove plug (6) .

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Illustration 23	g01291699

24. Install Tooling (P) .

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Illustration 24	g01291701

25. Remove plug (7) .

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Illustration 25	g01291706

26. Install Tooling (Q) .

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Illustration 26	g01291733
(8) Supply Oil

27. Connect hose assembly (8) from the pressurized flow meter to Tooling (K) .

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Illustration 27	g01291736
(9) Cooler Flow

28. Connect hose assembly (9) from Tooling (L) to the inlet of the No. 2 flow meter.

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Illustration 28	g01291748
(10) Return To Sump

29. Connect hose assembly (10) from the outlet of the No. 2 flow meter to the test bench sump.

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Illustration 29	g01291751
(11) Relief Valve Outlet

30. Connect hose assembly (11) from Tooling (Q) to the test bench sump.

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Illustration 30	g01291755

31. Connect hose assembly (12) from Tooling (K) to the inlet side of Tooling (R) .

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Illustration 31	g01291762

32. Tooling (R) .

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Illustration 32	g01291772
(13) Lockup Clutch Oil Supply

33. Connect hose assembly (13) from the output end of Tooling (R) to Tooling (P) .

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Illustration 33	g01291774
(14) Spindle Lubrication

34. Connect lube line (14) from the test bench to Tooling (C). Maintain an oil pressure of 275.8 kPa (40 psi).

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Illustration 34	g01291775
(15) Supply Pressure

35. Connect pressure gauge (15) to Tooling (K) .

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Illustration 35	g01291780
(16) Torque Converter Inlet Relief Pressure

36. Connect pressure gauge (16) to Tooling (M) .

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Illustration 36	g01291783
(17) Torque Converter Outlet Relief Pressure

37. Connect pressure gauge (17) to Tooling (N) .

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Illustration 37	g01291785
(18) Lockup Clutch Pressure

38. Connect pressure gauge (18) to Tooling (R) .

Test Procedure

Note: The torque converter inlet relief valve and the torque converter outlet relief valve MUST BE tested before the torque converter can be tested. Refer to Testing and Adjusting, SENR6869, "768C Tractor & 769C Truck Power Train", Testing and Adjusting, SENR6876, "772B Tractor & 773B Truck Power Train", Systems Operation, SENR6868, "768C Tractor & 769C Truck Power Train", or Systems Operation, SENR6875, "772B Tractor & 773B Truck Power Train" for additional information.

Warm-up Procedure

1. If you are using SAE 10W oil, warm the oil to 50 °C (125 °F). If you are using Mobil DTE11 oil, warm the oil to 34 °C (95 °F). Maintain this temperature for the duration of the test.

2. Turn the valve handle on Tooling (K) counterclockwise in order to remove restriction in the inlet flow.

3. Adjust the cooler flow to 132.4 ± 7.5 L/min (35 ± 2 US gpm).

4. Adjust Tooling (K) clockwise in order to increase the torque converter inlet pressure to 1379 ± 69 kPa (200.0 ± 10.0 psi).

5. Readjust the cooler flow to 132.4 ± 7.5 L/min (35 ± 2 US gpm).

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Illustration 38	g02664337

6. Rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1400 ± 10 rpm.

7. Open and close the valve on Tooling (R). The flow to the lockup clutch will purge any air from the system.

8. Maintain input speed, oil flow, and pressure for 5 minutes in order to purge the air from the system.

Torque Converter Leakage

1. Turn the valve handle on Tooling (K) counterclockwise in order to remove restriction in the inlet flow.

2. Adjust the cooler flow to 132.4 ± 7.5 L/min (35 ± 2 US gpm).

3. Adjust Tooling (K) in order to increase the torque converter inlet pressure to 1379 ± 69 kPa (200.0 ± 10.0 psi).

4. Readjust the cooler flow to 132 ± 7 L/min (35 ± 2 US gpm).

5. Record the flow at the torque converter inlet in Table 6.

6. Record the cooler flow at the No. 2 flow meter in Table 6.

Torque Converter Inlet Relief Valve Test

1. Turn the valve handle on Tooling (K) counterclockwise in order to remove restriction in the inlet flow.

2. Adjust the cooler flow to 132.4 ± 7.5 L/min (35 ± 2 US gpm).

3. Adjust Tooling (K) clockwise in order to increase the torque converter inlet pressure to 1379 ± 69 kPa (200.0 ± 10.0 psi).

4. Readjust the cooler flow to 132.4 ± 7.5 L/min (35 ± 2 US gpm).

5. Increase the restriction at the No. 2 flow meter until there is visible oil flow from Tooling (Q) .

6. Record the Torque Converter Inlet Pressure in Table 7. Reference 930 ± 34 kPa (135 ± 5 psi)

7. Remove all restriction at the No. 2 flow meter.

Lockup Clutch Test

1. Turn the valve handle on Tooling (K) counterclockwise in order to remove restriction in the inlet flow.

2. Adjust the cooler flow to 132.4 ± 7.5 L/min (35.0 ± 2.0 US gpm).

3. Adjust Tooling (K) clockwise in order to increase the torque converter inlet pressure to 1379 ± 69 kPa (200.0 ± 10.0 psi).

4. Readjust the cooler flow to 132.5 ± 7.5 L/min (35.0 ± 2.0 US gpm).

5. Open the valve on Tooling (R) in order to allow flow to the lockup clutch.

6. Record the supply pressure to the lockup clutch at pressure gauge (15) in Table 8. Reference 1310 ± 34 kPa (190 ± 5 psi)

7. Record the lockup clutch leakage at the flow meter on Tooling (R) in Table 8.

   Note: Lockup clutch leakage must not exceed 6.0 L/min (1.6 US gpm).

8. Close the ball valve on Tooling (R) in order to remove all pressure from the lockup clutch.

9. Stop rotation of the torque converter.

10. Discontinue oil flow and pressure to the torque converter inlet.

Contamination Control

1. Drain all oil from the torque converter.

2. Take an oil sample of the test bench oil supply. Oil contamination must be below ISO 16/13.

3. Record the results in Table 10.

4. Remove the torque converter from the test bench if the test bench oil supply is within specifications.

Specifications

Torque Converter Bench Test Data Sheet

Torque Converter Leakage

Torque Converter Inlet Relief Valve Test

Lockup Clutch Test

Contamination Control