Bench Test Procedure For A 24H and 24M Motor Grader Torque Converter{3101} Caterpillar

Motor Grader:

24H (S/N: 7KK1-UP)

24M (S/N: B9K1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS3448
01	Added new introduction and canceled part 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 transmission 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 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

Table 2

Machine Model	Torque Converter Arrangement
24H	8E-3673
24M	268-5675

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.

Canceled Part Numbers and Replaced Part Numbers

This document may not 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.

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.

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	294-0308	Test Fixture	1
B	9U-7211	Adapter Ring	1
	5S-2256	Bolt (1/2-13 x 1 3/4 inch)	8
C	1U-5798	Flywheel Assembly	1
D	1U-5999	Spindle Gp	1
	8B-7997	Bolt (1/2 -13 x 2 inch)	4
	3B-4506	Lockwasher	4
E	130-7575	Link Bracket	2
	9X-8880	Bolt (5/8-11 x 2 inch)	2
	5P-8247	Flat Washer	2
F	3F-7147	Bolt (1/2-13 x 1 1/2 inch)	6
	5P-8245	Flat Washer	6
G	1U-6721	Adapter Assembly	1
H	1U-9131	Adapter (1)	1
J	1U-9359	Adapter (2)	1
K	6V-3966	Nipple (Quick Disconnect)	1
L	8C-7313	Fitting	1
M	222-1110	O-Ring Seal	1
	1U-9870	Flange	1
	095-0670	Bolt (M12X1.75X45mm)	4
	6F-7732	Reducer Bushing	1
	004-5703	Pipe Adapter	1
	005-8615	Pipe Nipple	2
	3B-6555	Elbow	1
	6B-5072	Reducing Bushing	2
	6V-3966	Fitting As	2
	N1-600S (3)	Needle Valve	1
	4B-7770	Tee	2
	1L-4031	Service Tee	1
	8C-9024	Fitting As Nipple (Quick Disconnect)	1
	061-9593	Reducer Bushing	1
	3B-6555	Elbow	3
	6V-7788	Flow Meter Gp (5.0 L/min to 60.0 L/min (2.00 US gpm to 15.00 US gpm))	1
	004-7270	Pipe Fitting	1
	030-8307	Connector	1
	8F-8306	Reducer Bushing	1
N	222-1110	O-Ring Seal	1
	1P-4579	Half Flange	2
	9U-7446	Adapter	1
	095-0670	Bolt ((M12X1.75 X45 mm))	4
	6F-7732	Reducer Bushing	2
	IU-8304	45° Adapter	1
	8C-9024	Fitting As	1
P	277-2362	Transmission Analyzer Tool Gp	1
	9U-7496	Cable	1

( 1 )	This adapter is used for the small drive shaft.
( 2 )	This adapter is used with the large drive shaft.
( 3 )	Parker-Hannifin Identification Number

Installation Procedure

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Illustration 1	g01368724

1. Install Tooling (A) .

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Illustration 2	g01368733

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

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Illustration 3	g01368831

3. Install Tooling (C) to the Torque Converter.

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Illustration 4	g01368746

4. Install Tooling (D) .

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Illustration 5	g01368371

5. Install Tooling (E). Use a suitable lifting device to install the Torque Converter onto the test bench. The weight of the torque converter is 362.9 kg (800 lb).

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Illustration 6	g01357713

6. Use Tooling (F) in order to secure the torque converter to the test bench.

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Illustration 7	g01368748

7. 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 8	g01368750

8. Install Tooling (G) to Tooling (D) .

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Illustration 9	g01368774

9. Install Tooling (H) to Tooling (G) .

   Note: Tooling (H) will adapt to the small drive shaft. If you are using the large drive shaft, install Tooling (J) on Tooling (H) .

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Illustration 10	g01368773

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

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

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Illustration 11	g01368775

12. Install the drive shaft guard.

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Illustration 12	g01357723

13. Install Tooling (K) .

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Illustration 13	g01357850

14. Install Tooling (L) .

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Illustration 14	g01357871

15. Install Tooling (M) .

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Illustration 15	g01408648

16. Install Tooling (N) .

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Illustration 16	g01357943
(1) Supply Oil

17. Connect hose assembly (1) from the pressurized flow meter to Tooling (M) .

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Illustration 17	g01357949
(2) Cooler Supply

18. .Connect hose assembly (2) from Tooling (N) to the inlet of the No. 2 flow meter.

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Illustration 18	g01357962
(3) Lockup Supply

19. Connect hose assembly (3) from Tooling (M) to Tooling (L) .

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Illustration 19	g01398383

20. Connect hose assembly (4) from the outlet of the No. 2 flow meter to the oil drain.

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Illustration 20	g01368777
(4) Spindle Lubrication Oil Supply

21. Connect lube line (5) from the test bench to Tooling (D). Maintain an oil pressure of 275.8 kPa (40 psi).

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Illustration 21	g01357977
(6) Supply Pressure

22. Connect pressure gauge (6) .

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Illustration 22	g01357984
(7) Torque Converter Inlet Pressure

23. Connect pressure gauge (7) .

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Illustration 23	g01358143
(8) Outlet Relief Pressure

24. Connect pressure gauge (8) .

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Illustration 24	g01358155
(9) Lockup Pressure

25. Connect pressure gauge (9) .

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Illustration 25	g01389524

26. Tooling (P)

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Illustration 26	g01358183
(10) Lockup clutch solenoid

27. Connect test harness (10) to the Lockup Clutch Solenoid.

Test Procedure

Warm-up Procedure

1. Use SAE 10W oil. Warm the oil to 50 °C (125.0 °F). Maintain this temperature for the duration of the test.

2. Adjust the output flow at the No. 2 flow meter to 132.5 ± 9.5 L/min (35.00 ± 2.50 US gpm).

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Illustration 27	g02720621

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

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

Torque Converter Pressure And Leakage Test

1. Adjust Tooling (M) counterclockwise in order to remove restriction from inlet flow.

2. Adjust the output flow at the No. 2 flow meter to 132.5 ± 9.5 L/min (35.00 ± 2.50 US gpm).

3. Adjust Tooling (M) clockwise in order to increase supply pressure to 1516.8 ± 34.4 kPa (220.00 ± 5.00 psi).

4. Adjust the input rotation to 1400 ± 10 rpm.

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

6. Record the torque converter inlet pressure in Table 6.

7. Record the torque converter outlet relief pressure in Table 6.

8. To obtain the leakage, subtract the output flow from the input flow.

9. Record the calculation in Table 6.

Lockup Clutch Test

1. Adjust Tooling (M) counterclockwise in order to remove restriction in the inlet flow.

2. Adjust the output flow to 132.5 ± 9.5 kPa (35.00 ± 2.50 psi).

3. Adjust Tooling (M) in order to increase supply pressure to 1516.8 ± 34.4 L/min (220.00 ± 5.00 US gpm).

4. Readjust the output flow to 132.5 ± 9.5 L/min (35.00 ± 2.50 US gpm).

5. Use Tooling (P) to engage the lockup clutch.

6. Record the lockup clutch pressure in Table 7.

7. Record the leakage of the lockup clutch in Table 7.

8. Use Tooling (P) to disengage the lockup clutch.

9. Stop the input rotation.

10. Stop the input flow.

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 8.

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

Specifications

Table 4

General Specifications
Input Speed	1400 ± 10 rpm
Outlet Flow	132.0 ± 7.5 L/min (35.00 ± 2.50 US gpm)
Maximum Leakage	15.0 L/min (4.00 US gpm)
Supply Pressure	1517.0± 34.5 kPa (220.00± 5.00 psi)
Outlet Relief Pressure	414.0 ± 34.5 kPa (60.00 ± 5.00 psi)

Torque Converter Bench Test Procedure Data Sheet

Torque Converter Pressure and Leakage Test

Table 5

CATERPILLAR	Torque Converter Bench Test Data Sheet	Test Date:
		Model:
Work Order:		Serial No.:

Table 6

General Specifications
Input Speed	1400 ± 10 rpm
Torque Converter Inlet Flow (1)	L/Min (gpm)
Torque Converter Outlet Flow (2)	L/Min (gpm)
Leakage (3)	L/Min (gpm)
Torque Converter Inlet Pressure	kPa(psi)
Torque Converter Outlet 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

Lockup Clutch Test

Table 7

Lockup Clutch Test	Input Speed 1400 ± 10 rpm Torque Converter Outlet Flow (1) 132.0 ± 9.0 L/min (35.0 ± 2.5 US gpm) Supply Pressure 832.7902 ± 18.9271 L/min (220.0 ± 5.0 US gpm) Lockup Clutch Solenoid Energized
Lockup Clutch Pressure	kPa (psi)
Leakage (2)	L/Min (gpm)

( 1 )	Measured at the No. 2 flow meter
( 2 )	Leakage = Converter Inlet Flow − Converter Outlet Flow

Contamination Control

Table 8

ISO Particle Count

Sample the test bench oil supply.

________/________Particle Count

Table 9

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