- Off-Highway Truck/Tractor:
- 776B (S/N: 6JC1-UP)
- 776C (S/N: 2TK1-UP)
- 776D (S/N: 5ER1-UP; AFS1-UP)
- 777B (S/N: 4YC1-UP)
- 777C (S/N: 4XJ1-UP)
- 777D (S/N: AGC1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)
- 776C (S/N: 2TK1-UP)
Introduction
Revision     | Summary of Changes in REHS3466     | |
02     | 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 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. 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 need, use the following resources to communicate your request to Caterpillar Repair Process Engineering:
- Cat Dealer Techinical Communicator
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Machine Model     | Torque Converter Arrangement     |
---|---|
776B     | 8E-8999     |
776C     | 8E-8999     |
776D     | 8E-8999     |
777B     | 8E-8999     |
777C     | 8E-8999     |
777D     | 8E-8999     |
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.
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. |
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. |
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.
Required Tools     | |||
---|---|---|---|
Tool     | Part Number     | Part Description     | Qty     |
A     | 294-0308     | Test Fixture     | 1     |
B     | 1U-5119     | Adapter Ring     | 1     |
C     | 1U-5999     | Spindle Gp     | 1     |
8B-7997 | Bolt (1/2-13 x 2 inch)     | 4     | |
3B-4506 | Lockwasher     | 4     | |
D     | 138-7574     | Link Brackets     | 2     |
7X-0343 | Bolt (5/8-11 x 1.25 inch)     | 2     | |
8T-4122 | Hard Washer     | 2     | |
E     | 271-3644     | Drive Adapter     | 1     |
F     | 0S-1585     | Bolt     | 8     |
5P-8245 | Washer     | 8     | |
G     | 1U-6721     | Spindle Adapter     | 1     |
H     | 1U-9131     | Adapter Assembly     | 1     |
J     | 1U-9359     | Adapter Assembly     | 1     |
K     | 8C-9025     | Nipple (Plain)     | 1     |
6B-6765 | Elbow (90 degree)     | 1     | |
1L-4031 | Tee     | 1     | |
N1-600S (1) | Needle Valve     | 1     | |
6L-7349 | Nipple (Pipe)     | 1     | |
6V-8733 | Fitting (Union)     | 1     | |
1U-8300 | Fitting (Pipe to Port)     | 1     | |
2F-5277 | Bushing (Reducer)     | 1     | |
1U-9873 | Flange (Four Bolt)     | 1     | |
8B-7997 | Hex Socket Head Bolt (1/2-13 x 2.0)     | 4     | |
L     | 6V-7788     | Meter (Flow)     | 1     |
6V-7483 | Bushing (Reducer)     | 2     | |
148-0209 | Connector (37 Flared)     | 1     | |
281-5848 | Connector (37 Flared)     | 1     | |
M     | 1U-9873     | Flange (Four Bolt)     | 1     |
8B-7997 | Bolt (1/2-13 X 2.00 inch)     | 4     | |
7B-7138 | Elbow (90 degree)     | 1     | |
2F-5277 | Bushing (Reducer)     | 1     | |
8C-9024 | Fitting As     | 1     | |
N     | 6V-3965     | Nipple (Quick Disconnect)     | 1     |
O     | 6V-3965     | Nipple (Quick Disconnect)     | 1     |
P     | 6V-8724     | Elbow (90 degree)     | 1     |
Q     | 2R-6276     | Connector (37 Flared)     | 1     |
6V-5050 | O-ring     | 1     | |
R     | 6V-3965     | Nipple (Quick Disconnect)     | 1     |
S     | 6V-3965     | Nipple (Quick Disconnect)     | 1     |
T     |     | Power Supply Adjustable 0-30 VDC and 0-2.0 A     | 1     |
5p-5677 | Electrical Wire (18 AWG)     | 1     | |
7N-9738 | Plug Housing     | 1     | |
7N-7780 | Pin     | 1     | |
7N-7779 | Socket     | 1     |
( 1 ) | Parker - Hannifin Identification Number |
Installation Procedure
- Install Tooling (A) .
Illustration 1 | g01411904 |
- Install Tooling (B) onto Tooling (A) .
Illustration 2 | g01411899 |
- Install Tooling (C) .
Illustration 3 | g01291592 |
- Remove pump (1) .
Illustration 4 | g01411917 |
- Remove plug (2) .
Illustration 5 | g01411921 |
- Remove magnetic filter (3) .
Illustration 6 | g01411918 |
- Install Tooling (D) .
Illustration 7 | g01411396 |
- Install Tooling (E) .
Illustration 8 | g01411931 |
- Use a hoist to install the torque converter on the test bench. The weight of the torque converter is 680.4 kg (1500 lb).
Illustration 9 | g01411932 |
- Use Tooling (F) in order to secure the torque converter to Tooling (B) .
Illustration 10 | g01411936 |
- 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.
Illustration 11 | g01291616 |
- Install Tooling (G) .
Illustration 12 | g01291622 |
- 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) .
Illustration 13 | g01291642 |
- Align the torque converter with the drive shaft.
Illustration 14 | g01291645 |
- Connect the drive shaft to Tooling (H) .
- Install the drive shaft guard.
Illustration 15 | g01291648 |
- Install Tooling (K) .
Illustration 16 | g01411402 |
- Install Tooling (L) .
Illustration 17 | g01412184 |
- Install Tooling (M) .
Illustration 18 | g01411413 |
- Remove plug (4) .
Illustration 19 | g01411418 |
- Install Tooling (N) .
Illustration 20 | g01411421 |
- Remove plug (5) .
Illustration 21 | g01411423 |
- Install Tooling (O) .
Illustration 22 | g01411427 |
- Remove plug (6) .
Illustration 23 | g01411430 |
- Install Tooling (P) .
Illustration 24 | g01411431 |
- Remove plug (7) .
Illustration 25 | g01421637 |
- Install Tooling (Q) .
Illustration 26 | g01421638 |
- Remove plug (8) .
Illustration 27 | g01421644 |
- Install Tooling (R) .
Illustration 28 | g01421645 |
- Remove plug (9) .
Illustration 29 | g01421716 |
- Install Tooling (S) .
Illustration 30 | g01421648 |
- Connect hose assembly (10) from the pressurized flow meter to Tooling (K) .
Illustration 31 | g01421717 |
(10) Supply Oil |
- Connect hose assembly (11) from Tooling (M) to the inlet of the No. two flow meter.
Illustration 32 | g01421719 |
(11) Torque Converter Outlet Flow |
- Connect hose assembly (12) from the outlet of the No. two flow meter to the test bench sump.
Illustration 33 | g01421721 |
(12) Return To Sump |
- Connect hose assembly (13) from Tooling (L) to Tooling (Q) .
Illustration 34 | g01421724 |
Illustration 35 | g01421685 |
(13) Lockup Clutch Oil Supply |
- Connect lube line (14) from the test bench to Tooling (C). Maintain an oil pressure of 275.8 kPa (40 psi).
Illustration 36 | g01421726 |
(14) Spindle Lubrication |
- Connect pressure gauge (15) to Tooling (K) .
Illustration 37 | g01421762 |
(15) Torque Converter Supply Pressure |
- Connect pressure gauge (16) to Tooling (N) .
Illustration 38 | g01421765 |
(16) Torque Converter Inlet Relief Pressure |
- Connect pressure gauge (17) to Tooling (O) .
Illustration 39 | g01421897 |
(17) Torque Converter Outlet Relief Pressure |
- Connect pressure gauge (18) to Tooling R.
Illustration 40 | g01421649 |
(18) Lockup Clutch Pressure |
- Connect pressure gauge (19) to Tooling (S) .
Illustration 41 | g01421651 |
(19) Lockup Clutch Pilot Pressure |
- Connect Tooling (T) to lockup solenoid (20) .
Illustration 42 | g01421635 |
(T) Power Supply |
Illustration 43 | g01421628 |
(20) Lockup Solenoid |
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, SENR3143-01, "776B and 777B Truck Power Train", Testing and Adjusting, SENR5605-00, "776C and 777C Truck Power Train" or Testing and Adjusting, SENR6913-03, "776C, 777C, and 777D Off-Highway Truck/Tractors Power Train" for additional information.
Start Checks
Oil Requirements     | |
Oil Viscosity     | SAE 10W     |
Oil Temperature     | 49 °C (120 °F) to 54 °C (130 °F)     |
ISO Particle Count     | 16/13     |
Warm-up Procedure
- Begin using SAE 10W hydraulic oil. Warm the oil to 50 °C (125 °F). Maintain this temperature for the duration of the test.
- Turn the knob on Tooling (K) counterclockwise in order to remove any restriction to the inlet flow.
- Adjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).
- Adjust Tooling (K) clockwise in order to increase the supply pressure to 3447.4 ± 68.9 kPa (500 ± 10 psi).
- Readjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).
- Rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1300 ± 10 rpm.
Illustration 44 | g02720621 |
- Maintain input speed, oil flow, and pressure for 5 minutes in order to purge the air from the system.
Torque Converter Leakage and Lockup Clutch Pilot Pressure
- Turn the knob on Tooling (K) counterclockwise in order to remove any restriction to the inlet flow.
- Adjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).
- Adjust Tooling (K) clockwise in order to increase the supply pressure to 3447.4 ± 68.9 kPa (500 ± 10 psi).
- Readjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).
- Rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1300 ± 10 rpm.
- Record the Torque Converter Inlet Flow in Table 7.
- Record the Torque Converter Outlet Flow at the No. 2 flow meter in Table 7.
- Record the Lockup Clutch Pilot Pressure at pressure gauge (19) in Table 8.
Torque Converter Inlet Relief Valve Test
- Turn the knob on Tooling (K) counterclockwise in order to remove any restriction to the inlet flow.
- Adjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).
- Adjust Tooling (K) clockwise in order to increase the supply pressure to 3447.4 ± 68.9 kPa (500 ± 10 psi).
- Readjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).
- Rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1300 ± 10 rpm.
- Adjust the load valve on the No. 2 flow meter that is connected to the torque converter outlet until there is visible oil flow from Tooling (P) .
- Record the Torque Converter Inlet Relief Pressure in Table 9. Reference 930.8 ± 34.5 kPa (135.0 ± 5.0 psi)
Lockup Clutch Test
- Turn the knob on Tooling (K) counterclockwise in order to remove any restriction to the inlet flow.
- Adjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).
- Adjust Tooling (K) clockwise in order to increase the supply pressure to 3447.4 ± 68.9 kPa (500 ± 10 psi).
- Readjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).
- Rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1300 ± 10 rpm.
- Adjust Tooling (T) to 24 VDC and 0.75 amp in order to engage the lockup clutch.
- Record the Lockup Clutch Pressure at pressure gauge (18) in Table 10.
- Record the Lockup Clutch Leakage on Tooling (L) in Table 10.
Note: Lockup Clutch Leakage must not exceed 15.2 L/min (4.0 US gpm).
- Adjust Tooling (T) to 0.0 Amps in order to disengage the lockup clutch.
- Stop rotation of the torque converter.
- Discontinue all oil flow and pressure to the Torque Converter Inlet.
Lockup Clutch Primary Pressure
- Remove cover (21) from the Lockup Clutch Valve Group.
Illustration 45 | g01422078 |
- Remove load piston plug (22) .
Illustration 46 | g01422082 |
- Reinstall cover (21) .
Illustration 47 | g01422078 |
- Turn the knob on Tooling (K) counterclockwise in order to remove any restriction to the inlet flow.
- Adjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).
- Adjust Tooling (K) clockwise in order to increase the supply pressure to 3447.4 ± 68.9 kPa (500 ± 10 psi).
- Readjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).
- Rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1300 ± 10 rpm.
- Adjust Tooling (T) to 24 VDC and 0.75 amp in order to engage the lockup clutch.
- Measure the lockup clutch pressure at Tooling (18) and record the value in Table 11. Reference 1175 ± 35 kPa (170.5 ± 5.0 psi)
- Adjust Tooling (T) to 0.0 amps in order to disengage the lockup clutch.
- Stop rotation of the torque converter.
- Discontinue all oil flow and pressure to the Torque Converter Inlet.
- Remove cover (21) from the Lockup Clutch Valve Group.
- Reinstall load piston plug (22) .
- Reinstall cover (21) .
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 12.
- 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     |
Inlet Flow (Torque Converter)     | 159.0 ± 3.8 L/min (42 ± 1 US gpm)     |
Supply Pressure     | 3447.4 ± 68.9 kPa (500 ± 10 psi)     |
Maximum Torque Converter Leakage     | 15.2 L/min (4.0 US gpm)     |
Inlet Relief Valve     | 930.0 ± 35.0 kPa (135.0 ± 5.0 psi)     |
Outlet Relief Valve     | 551.6 ± 34.5 kPa (80 ± 5 psi)     |
Maximum Lockup Clutch Leakage     | 15.2 L/min (4.0 US gpm)     |
Lockup Clutch Supply Pressure     | 2138.0 ± 34.0 kPa (310.0 ± 5.0 psi)     |
Lockup Clutch Pilot Pressure     | 1725.0 ± 70.0 kPa (250.0 ± 10.0 psi)     |
Lockup Clutch Primary Pressure     | 1175 ± 35 kPa (170.5 ± 5.0 psi)     |
Torque Converter Bench Test Data Sheet
CATERPILLAR     | Torque Converter Bench Test Data Sheet     | Test Date:     |
Models: 776B, 776C, 776D, 777B, 777C, 777D | ||
Work Order:     | Serial No.:     |
Torque Converter Leakage
Torque Converter Leakage     | ||
Input Speed (1300 ± 10 rpm) Inlet Flow 159.0 ± 3.8 L/min (42 ± 1 US gpm) Supply Pressure 3447.4 ± 68.9 kPa (500 ± 10 psi)     |
Inlet Flow (Torque Converter) (1)     |
L/Min (gpm)     |
Outlet Flow (Torque Converter) (2) |
L/Min (gpm)     |
|
Leakage (3) |
L/Min (gpm)     |
( 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 Lockup Clutch Pilot Pressure
Lockup Clutch Pilot Pressure (1)     | ||||
Input Speed (1300 ± 10 rpm) Inlet Flow 159.0 ± 3.8 L/min (42 ± 1 US gpm) Supply Pressure 3447.4 ± 68.9 kPa (500 ± 10 psi)     |
kPa (psi)     |
( 1 ) | The Lockup Clutch Pilot Pressure is measured at pressure gauge (19) . |
Torque Converter Inlet Relief Valve Test
Torque Converter Inlet Relief Valve Test (1)     | ||||
Input Speed (1300 ± 10 rpm) Inlet Flow 159.0 ± 3.8 L/min (42 ± 1 US gpm) Supply Pressure 3447.4 ± 68.9 kPa (500 ± 10 psi)     |
kPa (psi)     |
( 1 ) | The pressure for the Inlet Relief Valve is measured at pressure gauge (16) . |
Torque Converter Lockup Clutch Pressure
Torque Converter Lockup Clutch Pressure     | ||
Input Speed (1300 ± 10 rpm) Inlet Flow 159.0 ± 3.8 L/min (42 ± 1 US gpm) Supply Pressure 3447.4 ± 68.9 kPa (500 ± 10 psi)     |
Lockup Clutch Pressure (1)     | kPa (psi)     |
Lockup Clutch Leakage (2) | L/Min (gpm)     |
( 1 ) | The Lockup Clutch Pressure is measured at pressure gauge (18) . |
( 2 ) | The Lockup Clutch Leakage is measured at Tooling (L) . |
Lockup Clutch Primary Pressure
Lockup Clutch Primary Pressure (1)     | ||||
Input Speed (1300 ± 10 rpm) Inlet Flow 159.0 ± 3.8 L/min (42 ± 1 US gpm) Supply Pressure 3447.4 ± 68.9 kPa (500 ± 10 psi)     |
kPa (psi)     |
( 1 ) | The Lockup Clutch Primary Pressure is measured at pressure gauge (18) . |
Contamination Control
ISO Particle Count     | Sample the test bench oil supply.     |
________/________Particle Count     |
______________________________________ Technician     |
______________________________________ Supervisor     |