- Articulated Truck:
- D35-HP (S/N: 3FD1-UP)
- D400 (S/N: 1MD1-UP)
- Off-Highway Truck/Tractor:
- 69D (S/N: 9SS1-UP)
- 768C (S/N: 02X1-UP)
- 769C (S/N: 01X1-UP)
- 769D (S/N: 5TR1-UP)
- 768C (S/N: 02X1-UP)
- Quarry Truck:
- 771C (S/N: 3BJ1-UP)
- 771D (S/N: 6JR1-UP)
Introduction
| Revision | Summary of Changes in REHS3439 | |
| 01 | Updated introduction and added Canceled Part Numbers section. | |
© 2012 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. Rotating a torque converter provides the most conclusive evaluation. This 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 need, use the following resources to communicate your request to Caterpillar Repair Process Engineering:
- Cat Dealer Techinical Communicator
- Dealer Solution Network
- Cat Technical Representative
- Knowledge Network
| Machine Model | Torque Converter Arrangement |
| 768C | 6T-4675 |
| 769C | 6T-4675 |
| 769D | 6T-4675 |
| 771C | 6T-4675 |
| 771D | 6T-4675 |
| D35-HP | 6T-4675 |
| D400 | 6T-4675 |
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. |
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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.
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 294-0308 | Test Fixture | 1 |
| B | 9U-7211 | Adapter Ring | 1 |
| 3F-7147 | Bolt (1/2-13X1.5 inch) | 8 | |
| C | 1U-5999 | Spindle Assembly | 1 |
| 8B-7997 | Bolt (1/2-13X2 inch) | 4 | |
| 3B-4506 | Lockwasher | 4 | |
| D | 1U-5798 | Drive Adapter Gp | 1 |
| 0S-1585 | Bolt (1/2-13X1.5 inch) | 2 | |
| 5P-8245 | Hard Washer | 2 | |
| E | 138-7574 | Link Bracket | 2 |
| 7X-0343 | Bolt (5/8-11X1.25 inch) | 2 | |
| 8T-4122 | Hard Washer | 2 | |
| F | 1U-6721 | Adapter As | 1 |
| G | 1U-9131 | Adapter (1) | 1 |
| H | 1U-9359 | Adapter (2) | 1 |
| J | 222-1110 | O-Ring Seal | 1 |
| 1U-9870 | Flange | ||
| 5S-2256 | Bolt (1/2-13X1.75 inch) | 1 | |
| 6F-7732 | Bushing | 1 | |
| 004-5703 | Bushing | 1 | |
| 005-8615 | Nipple | 2 | |
| 3B-6555 | Elbow | 1 | |
| 120-6843 | Ball Valve | 1 | |
| 4B-7770 | Tee (Pipe) | 1 | |
| 1L-4031 | Tee | 1 | |
| 061-9593 | Bushing | 1 | |
| 6B-5072 | Bushing | 1 | |
| 6V-3966 | Nipple (Quick Disconnect) | 1 | |
| 8C-9024 | Nipple (Quick Disconnect) | 1 | |
| K | 030-8307 | Connector | 1 |
| 4C-8689 | Flow Meter (0 - 18.92 L/min (0 - 5 US gpm)) | 1 | |
| 004-5703 | Adapter | 1 | |
| 6V-1881 | Elbow | 1 | |
| 6K-3459 | Connector | 1 | |
| L | 222-1110 | O-Ring Seal | 1 |
| 9U-7446 | Adapter | 1 | |
| 1U-8301 | Fitting | 1 | |
| 8C-9024 | Nipple (Quick Disconnect) | 1 | |
| 1P-4579 | Half Flange | 2 | |
| 0S-1621 | Bolt (1/2-13X1 inch) | 4 | |
| M | 004-6683 | Nipple (Pipe) | 1 |
| 3B-6495 | Elbow | 1 | |
| N | 6V-3965 | Nipple (Quick Disconnect) | 1 |
| 3J-1907 | O-Ring Seal | 1 | |
| P | 6V-3965 | Nipple (Quick Disconnect) | 1 |
| 3J-1907 | O-Ring Seal | 1 | |
| Q | 6V-3965 | Nipple (Quick Disconnect) | 2 |
| 3J-1907 | O-Ring Seal | 2 | |
| R |
3P-1427 | Port Connector | 1 |
| 3D-2824 | O-Ring Seal | 1 | |
| S | DC Power Supply (Adjustable 0-30 VDC - 0-2.0 A) | 1 | |
| 5P-5677 | Electrical Wire (18 AWG) | 1 | |
| 7N-9737 | Plug Housing | 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) .
 | |
| Illustration 1 | g01327310 |
- Install Tooling (B) to Tooling (A) .
 | |
| Illustration 2 | g01327311 |
- Install Tooling (C) to Tooling (A) .
 | |
| Illustration 3 | g01327312 |
- Install Tooling (D) .
 | |
| Illustration 4 | g01327313 |
- Install Tooling (E) .
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| Illustration 5 | g01327317 |
- Use a hoist to install the torque converter on the test bench. The weight of the torque converter is 437.71 kg (965 lb).
 | |
| Illustration 6 | g01327318 |
- Tighten the collet on Tooling (C) in order to connect Tooling (C) to Tooling (D) .
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.
 | |
| Illustration 7 | g01327429 |
- Install Tooling (F) to Tooling (C) .
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| Illustration 8 | g01327431 |
- 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) .
 | |
| Illustration 9 | g01327433 |
- Align the torque converter with the input drive shaft.
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| Illustration 10 | g01327434 |
- Connect the input drive shaft to Tooling (G) .
- Install the drive shaft guard.
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| Illustration 11 | g01327436 |
- Remove filter assembly (1) .
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| Illustration 12 | g01327438 |
- Install Tooling (J) .
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| Illustration 13 | g01327445 |
- Install Tooling (K) .
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| Illustration 14 | g01327481 |
- Install Tooling (L) .
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| Illustration 15 | g01327494 |
- Remove threaded plug (2) .
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| Illustration 16 | g01327495 |
- Install Tooling (M) .
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| Illustration 17 | g01327521 |
- Remove threaded plug (3) .
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| Illustration 18 | g01327533 |
- Install Tooling (N) .
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| Illustration 19 | g01327523 |
- Remove threaded plug (4) .
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| Illustration 20 | g01327539 |
- Install Tooling (P) .
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| Illustration 21 | g01327540 |
- Remove threaded plug (5) and threaded plug (6) .
 | |
| Illustration 22 | g01327547 |
- Install Tooling (Q) .
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| Illustration 23 | g01327548 |
- Remove threaded plug (7) .
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| Illustration 24 | g01327559 |
- Install Tooling (R) .
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| Illustration 25 | g01327560 |
- Connect Hose Assembly (8) from the pressurized flow meter on the test bench to Tooling (J) .
 | |
| Illustration 26 | g01327648 |
(8) Supply Oil | |
- Connect Hose Assembly (9) from Tooling (L) to the inlet of the "Number 2" flow meter.
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| Illustration 27 | g01327651 |
(9) Torque Converter Outlet | |
- Connect Hose Assembly (10) from the outlet of the "Number 2" flow meter to the oil drain.
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| Illustration 28 | g01327681 |
- Connect Hose Assembly (11) from Tooling (K) to Tooling (R) .
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| Illustration 29 | g01327658 |
(11) Lockup Clutch Supply | |
- Connect lubrication line (12) from the test bench to Tooling (C). Maintain an oil pressure of 275.8 kPa (40.0 psi).
 | |
| Illustration 30 | g01327698 |
(12) Spindle Lubrication Oil Supply | |
- Connect pressure gauge (13) to Tooling (J) .
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| Illustration 31 | g01327703 |
(13) Supply Pressure | |
- Connect pressure gauge (14) to Tooling (N) .
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| Illustration 32 | g01327704 |
(14) Inlet Relief Pressure | |
- Connect pressure gauge (15) to Tooling (P) .
 | |
| Illustration 33 | g01327705 |
(15) Outlet Relief Pressure | |
- Connect pressure gauge (16), as shown.
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| Illustration 34 | g01327706 |
(16) Lockup Clutch Pressure | |
- Connect pressure gauge (17) to Tooling (Q), as shown.
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| Illustration 35 | g01327707 |
(17) Parking Brake Release Pressure | |
- Connect pressure gauge (18) to Tooling (Q), as shown.
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| Illustration 36 | g01327727 |
(18) Lockup Clutch Pilot Pressure | |
- Install Tooling (S) .
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| Illustration 37 | g01327770 |
Tooling (S) | |
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| Illustration 38 | g01327734 |
Test Procedure
Warmup 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 to 34 °C (95 °F). Maintain this temperature for the duration of the test.
- Adjust Tooling (J) counterclockwise in order to remove restriction in the inlet flow.
- Adjust the output flow to 132.5 L/min (35.0 US gpm).
- Adjust Tooling (J) clockwise in order to increase supply pressure to 3447.4 ± 69.0 kPa (500.0 ± 10.0 psi).
- Readjust the output flow to 132.5 L/min (35.0 US gpm).
- Rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1400 ± 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.
 | |
| Illustration 39 | g02720621 |
- 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 (J) counterclockwise in order to remove restriction in the inlet flow.
- Adjust the output flow to 132.5 L/min (35.0 US gpm).
- Adjust Tooling (J) clockwise in order to increase supply pressure to 3447.4 ± 69.0 kPa (500.0 ± 10.0 psi).
- Readjust the output flow to 132.5 L/min (35.0 US gpm).
- Adjust the input rotation to 1400 ± 10 rpm.
- Record the torque converter inlet flow at the pressurized flow meter in Table 6.
- Record the torque converter inlet relief pressure in Table 6.
- Record the torque converter outlet relief pressure in Table 6.
- Record the parking brake release pressure in Table 6.
- Record the lockup clutch pilot pressure in Table 6.
- To obtain leakage, subtract the output flow from the input flow.
- Record the calculation in Table 6.
Torque Converter Inlet Relief Valve Test
- Adjust Tooling (J) counterclockwise in order to remove restriction in the inlet flow.
- Adjust the output flow to 132.5 L/min (35.0 US gpm).
- Adjust Tooling (J) in order to increase supply pressure to 3447.4 ± 69.0 kPa (500.0 ± 10.0 psi).
- Readjust the output flow to 132.5 L/min (35.0 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 (M) .
- Record the torque converter inlet pressure in Table 7.
Lockup Clutch Test
- Adjust Tooling (J) counterclockwise in order to remove restriction in the inlet flow.
- Adjust the output flow to 132.5 L/min (35.0 US gpm).
- Adjust Tooling (J) in order to increase supply pressure to 3447.4 ± 69.0 kPa (500.0 ± 10.0 psi).
- Readjust the output flow to 132.5 L/min (35.0 US gpm).
- Adjust Tooling (S) to 24 VDC and 0.75 amp in order to engage the lockup clutch.
- Record lockup clutch pressure in Table 8.
- Record the lockup clutch leakage in Table 8.
- Record the parking brake release pressure in Table 8.
- Record the lockup clutch pilot pressure in Table 8.
- Adjust Tooling (S) to 0.000 amp in order 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 | 1400 ± 10 rpm |
| Torque Converter Outlet Flow | 132.5 L/min (35.0 US gpm) |
| Maximum Torque Converter Leakage | 11.4 L/min (3.0 US gpm) |
| Inlet Relief Pressure | 517.1 ± 69.0 kPa (75.0 ± 10.0 psi) |
| Parking Brake Release Pressure | 3447.4 ± 34.5 kPa (500.0 ± 5.0 psi) |
| Outlet Relief Pressure | 413.7 ± 34.5 kPa (60.0 ± 5.0 psi) |
| Lockup Clutch Supply Pressure | 1551.3 ± 34.5 kPa (225.0 ± 5.0 psi) |
| Lockup Clutch Pilot Pressure | 1723.7 ± 34.5 kPa (250.0 ± 5.0 psi) |
| Maximum Lockup Clutch Leakage | 6.1 L/min (1.6 US gpm) |
Torque Converter Bench Test Data Sheet
| CATERPILLAR | Torque Converter Bench Test Data Sheet | Test Date: |
| Model: | ||
| Work Order: | Serial No.: | |
Torque Converter Pressure and Leakage Test
| Torque Converter Pressure and Leakage | |
| Input Speed | 1400 ± 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) |
| Parking Brake Release Pressure | kPa (psi) |
| Lockup Clutch Pilot 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 (1400 ± 10 rpm) Output Flow 132.5 L/min (35.0 US gpm) Supply Pressure 3447.4 ± 69.0 kPa (500.0 ± 10.0 psi) |
kPa (psi) |
|||
| ( 1 ) | Inlet Relief Valve pressure is measured at pressure gauge (14) . |
Lockup Clutch Test
| Torque Converter Lockup Clutch | ||
| Input Speed (1400 ± 10 rpm) Output Flow 132.5 L/min (35.0 US gpm) Supply Pressure 3447.4 ± 69.0 kPa (500.0 ± 10.0 psi) |
Lockup Clutch Pressure (1) | kPa (psi) |
| Lockup Clutch Leakage (2) | L/Min (gpm) |
|
| Parking Brake Release Pressure | kPa (psi) |
|
| Lockup Clutch Pilot Pressure (3) | kPa (psi) |
|
| ( 1 ) | The Lockup Clutch Pressure is measured at pressure gauge (16) . |
| ( 2 ) | TheLockup Clutch Leakage is measured at Tooling (K) . |
| ( 3 ) | The Lockup Clutch Pilot Pressure is measured at pressure gauge (18) . |
Contamination Control
| ISO Particle Count | Sample the test bench oil supply. |
________/________Particle Count |
| ______________________________________ Technician |
______________________________________ Supervisor |