- Off-Highway Truck/Tractor
- 777F (S/N: JRP1-UP)
- 777G (S/N: GT71-UP; T5A1-UP; RDR1-UP; T4Y1-UP)
- Quarry Truck
- 773G (S/N: G771-UP)
Introduction
| Revision | Summary of Changes in REHS3438 | |
| 02 | Updated Title with 777G.
Updated Table 2with 777G. Updated Table 3. Updated introduction and safety graphics. Standardized |
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| 01 | Updated introduction and added Canceled Part Numbers section. | |
© 2018 Caterpillar All Rights Reserved. This document is for the use of Caterpillar Dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.
This document 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 transmission ensures correct assembly and operation of the component. Rotating a transmission provides the most conclusive evaluation. Testing allows the dealer to ensure that the transmission will operate properly in the machine. The specifications in this document are specific to bench testing the component. Every effort has been made 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 document must be used with the latest technical information that is available from Caterpillar.
For technical questions when using this document, work with your Dealer Technical Communicator (TC).
To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.
| Machine Model | Torque Converter Arrangement |
| 777F | |
| 777G |
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.
Important Safety Information
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| Illustration 1 | g02139237 |
Follow all safety warnings. Most accidents that involve product operation, maintenance, or repair are caused by failure to observe safety warnings. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. Personnel must be properly trained to perform maintenance, repair, or operate any machine. Safety precautions and warnings are provided this instruction and on Caterpillar products. These warnings should be observed before performing any procedures. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are not all inclusive.
The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The “WARNING” Safety Alert Symbol is shown in illustration below.
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| Illustration 2 | g00008666 |
This safety alert symbol means:
Pay Attention!
Become Alert!
Your Safety is Involved.
The message that appears under the safety alert symbol explains the hazard.
Operations that may cause product damage are identified by "NOT" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.
The information, the specifications, and the illustrations that exist in this document are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.
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 to develop this test procedure. These tools are suggested and may very depending on availability and bench configuration.
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | Test Fixture | 1 | |
| B | Adapter Ring | 1 | |
| Bolt (1/2-13X1.5 inch) | 8 | ||
| C | Drive Adapter | 1 | |
| D | Spindle Assembly | 1 | |
| Bolt (1/2-13X2 inch) | 4 | ||
| Lockwasher | 4 | ||
| E | Link Bracket | 2 | |
| Bolt (5/8-11x1.25 inch) | 2 | ||
| Hard Washer | 2 | ||
| F | Adapter Assembly | 1 | |
| G | Adapter(1) | 1 | |
| H | Adapter(2) | 1 | |
| J | Half Flange | 2 | |
| Bolt (1/2-13X1.5 inch) | 4 | ||
| Cover | 1 | ||
| O-Ring Seal | 1 | ||
| K | O-Ring Seal | 1 | |
| Flange | 1 | ||
| Bolt (1/2-13X1.75 inch) | 4 | ||
| Bushing | 1 | ||
| Nipple (Pipe) | 2 | ||
| Tee | 1 | ||
| Ball Valve | 1 | ||
| Tee (Pipe) | 1 | ||
| Nipple (Quick Disconnect) | 1 | ||
| Bushing | 1 | ||
| Bushing | 1 | ||
| Nipple (Quick Disconnect) | 1 | ||
| Fitting | 2 | ||
| L | O-Ring Seal | 1 | |
| Flange | 1 | ||
| Bolt (1/2-13X1.75 inch) | 4 | ||
| Bushing | 1 | ||
| Fitting | 1 | ||
| Nipple (Quick Disconnect) | 1 | ||
| M | Connector | 1 | |
| Flow Meter ( |
1 | ||
| Adapter | 1 | ||
| Elbow | 1 | ||
| Connector | 1 | ||
| N | Elbow | 1 | |
| P | Fitting | 1 | |
| Q | Transmission Analyzer Gp | 1 | |
| Adapter Cable Assembly (Test) | 1 | ||
| (1) | This adapter is used for the small drive shaft. |
| (2) | This adapter is used with the large drive shaft. |
Installation Procedure
- Install Tooling (A).
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Illustration 4 g01325448 - Install Tooling (B) to Tooling (A).
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Illustration 5 g01325452 - Remove flywheel pilot (1).
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Illustration 6 g01325453 - Install Tooling (C).
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Illustration 7 g01325458 - Install Tooling (D) to Tooling (A).
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Illustration 8 g01325455 - Install Tooling (E).
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Illustration 9 g01325456 - Use a hoist to install the torque converter on the test bench. The weight of the torque converter is
598.74 kg (1320 lb) .Show/hide table
Illustration 10 g01325474 - Tighten the collet on Tooling (D) in order to connect Tooling (D) to Tooling (C).
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 11 g01325476 - Install Tooling (F) to Tooling (D).
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Illustration 12 g01325477 - Install Tooling (G) to Tooling (F). Tooling (G) will adapt to the small drive shaft. If you are using the large drive shaft, install Tooling (H) on Tooling (G).
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Illustration 13 g01325478 - Align the torque converter with the input drive shaft.
- Connect the input drive shaft to Tooling (G).
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Illustration 14 g01325479 - Install the drive shaft guard.
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Illustration 15 g01325485 - Remove filter assembly (2).
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Illustration 16 g01325486 - Install Tooling (J).
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Illustration 17 g01325487 - Install Tooling (K).
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Illustration 18 g01325488 - Install Tooling (L).
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Illustration 19 g01325501 - Install Tooling (M).
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Illustration 20 g01325502 - Remove threaded plug (3).
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Illustration 21 g01325503 - Install Tooling (N).
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Illustration 22 g01325505 - Install Tooling (P).
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Illustration 23 g01325514 (4) Supply Oil - Connect Hose Assembly (4) from the pressurized flow meter on the test bench to Tooling (K).
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Illustration 24 g01325515 (5) Torque Converter Outlet - Connect Hose Assembly (5) from Tooling (L) to the inlet of the "Number 2" flow meter.
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Illustration 25 g01325516 - Connect Hose Assembly (6) from the outlet of the "Number 2" flow meter to the oil drain.
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Illustration 26 g01325517 (7) Lockup Clutch Supply - Connect Hose Assembly (7) from Tooling (M) to Tooling (P).
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Illustration 27 g01325558 (8) Spindle Lubrication Oil Supply - Connect lubrication line (8) from the test bench to Tooling (D). Maintain an oil pressure of
275.8 kPa (40.0 psi) .Show/hide table
Illustration 28 g01325561 (9) Supply Pressure - Connect pressure gauge (9) to Tooling (K).
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Illustration 29 g01325563 (10) Inlet Relief Pressure - Connect pressure gauge (10) to Tooling (N).
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Illustration 30 g01325565 (11) Outlet Relief Pressure - Connect pressure gauge (11).
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Illustration 31 g01325567 (12) Lockup Clutch Pressure - Connect pressure gauge (12) to test port (13).
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Illustration 32 g01326006 Tooling (Q) Show/hide table
Illustration 33 g01325589 - Install Tooling (Q).
Note: Refer to Tool Operating Manual, NEHS0966 for the correct operating instructions.
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| Illustration 3 | g01325447 |
Warm-up Procedure
- 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 to34 °C (95 °F) . Maintain this temperature for the duration of the test. - Adjust Tooling (K) counterclockwise in order to remove restriction in the inlet flow.
- Adjust the output flow to
151.4 L/min (40.0 US gpm) . - Adjust Tooling (K) clockwise in order to increase supply pressure to
2240.8 ± 34.5 kPa (325.0 ± 5.0 psi) . - Readjust the output flow to
151.4 L/min (40.0 US gpm) .Show/hide table
Illustration 34 g02720621 - Rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1300 ± 10 rpm.
Note: The input shaft will be rotated in a counterclockwise direction for the duration of this test. The direction of rotation is determined as you face the drive motor of the test bench.
- Maintain input speed, oil flow, and pressure for 5 minutes in order to purge air from the system.
Torque Converter Pressure and Leakage Test
- Adjust Tooling (K) counterclockwise in order to remove restriction in the inlet flow.
- Adjust the output flow to
151.4 L/min (40.0 US gpm) . - Adjust Tooling (K) clockwise in order to increase supply pressure to
2240.8 ± 34.5 kPa (325.0 ± 5.0 psi) . - Readjust the output flow to
151.4 L/min (40.0 US gpm) . - Adjust the input rotation to 1300 ± 10 rpm.
- Record the torque converter inlet flow at the pressurized flow meter in Table 6.
- Record the torque converter inlet pressure in Table 6.
- Record the torque converter outlet relief pressure in Table 6.
- To obtain leakage, subtract the output flow from the input flow.
- Record the calculation in Table 6.
- Record torque converter inlet relief pressure in Table 6.
Torque Converter Inlet Relief Valve Test
- Adjust Tooling (K) counterclockwise in order to remove restriction in the inlet flow.
- Adjust the output flow to
151.4 L/min (40.0 US gpm) . - Adjust Tooling (M) in order to increase supply pressure to
2240.8 ± 34.5 kPa (325.0 ± 5.0 psi) . - Readjust the output flow to
151.4 L/min (40.0 US gpm) . - Adjust the relief valve on the "Number 2" flow meter that is connected to the torque converter outlet until there is visible oil flow from Tooling (N).
- Record the torque converter inlet pressure in Table 7.
Lockup Clutch Test
- Adjust Tooling (K) counterclockwise in order to remove restriction in the inlet flow.
- Adjust the output flow to
151.4 L/min (40.0 US gpm) . - Adjust Tooling (M) in order to increase supply pressure to
2240.8 ± 34.5 kPa (325.0 ± 5.0 psi) . - Readjust the output flow to
151.4 L/min (40.0 US gpm) . - Use Tooling (Q) to engage the lockup clutch.
- Record lockup clutch pressure in Table 8.
- Record the lockup clutch leakage in Table 8.
- Use Tooling (Q) to disengage the lockup clutch.
- Stop the input rotation.
- Stop the input flow.
Contamination Control
- Drain all oil from the torque converter.
- Take an oil sample of the test bench oil supply. Oil contamination must be below ISO 16/13.
- Record the results in Table 9.
- Remove the torque converter from the test bench if the test bench oil supply is within specifications.
Specifications
| General Specifications | |
| Input Speed | 1300 ± 10 rpm |
| Torque Converter Outlet Flow | |
| Maximum Torque Converter Leakage | |
| Supply Pressure | |
| Inlet Relief Pressure | |
| Inlet Relief Pressure (Restricted) | |
| Outlet Relief Pressure | |
| Lockup Clutch Supply Pressure | |
| Maximum Lockup Clutch Leakage | |
Torque Converter Bench Test Data Sheet
| CATERPILLAR | Transmission Bench Test Data Sheet | Test Date:______ |
| Model: ______ | ||
| Work Order:__________ | Serial No.:______ | |
Torque Converter Pressure and Leakage Test
| Torque Converter Pressure and Leakage Test | |
|---|---|
| Input Speed | 1300 ± 10 rpm |
| Inlet Flow (Torque Converter)(1) |
L/Min (gpm) |
| Outlet Flow (Torque Converter)(2) |
L/Min (gpm) |
| Leakage(3) |
L/Min (gpm) |
| Torque Converter Inlet Relief Pressure | kPa (psi) |
| Torque Converter Outlet Relief Pressure | kPa (psi) |
| (1) | Measured at the pressurized flow meter |
| (2) | Measured at the No. 2 flow meter |
| (3) | Leakage = Converter Inlet Flow − Converter Outlet Flow |
Torque converter Inlet Relief Valve Test
| Torque Converter Inlet Relief Valve(1) | ||||
|---|---|---|---|---|
| Input Speed (1300 ± 5 rpm)
Output Flow Supply Pressure |
kPa (psi) |
|||
| (1) | The pressure for the Inlet Relief Valve is measured at pressure gauge (10). |
Lockup Clutch Test
| Torque Converter Lockup Clutch | ||
|---|---|---|
| Input Speed (1300 ± 5 rpm)
Output Flow Supply Pressure |
Lockup Pressure(1) | kPa (psi) |
| Lockup Clutch Leakage(2) | L/Min (gpm) |
|
| (1) | The Lockup Clutch Pressure is measured at pressure gauge (12). |
| (2) | The Lockup Clutch Leakage is measured at Tooling (M). |
Contamination Control
| ISO Particle Count | Sample the test bench oil supply. *ISO 4406 is 16/13 or better |
________/________Particle Count |
______________________________________ Technician |
______________________________________ Supervisor |