Bench Test Procedure for a 797 and 797B Off-Highway Truck Torque Converter Inlet Relief Valve, Torque Converter Outlet Relief Valve, and Transmission Main Relief Valve {3030, 3101, 3133, 3210} Caterpillar

Off Highway Truck

797 (S/N: 5YW1-UP)

797B (S/N: JSM1-UP)

Introduction

© 2016 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. Information contained in this document is considered Caterpillar: Confidential Yellow.

This special instruction contains the necessary information that is required to bench test-specific relief valves. Refer to Table 2 for the correct groups. Bench testing the relief valve ensures correct assembly and operation of the component. This allows the dealer to ensure that the relief valve will operate properly on the component. The specifications in this guideline are specific to bench testing the relief valve. 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

• Dealer Solution Network

• Caterpillar Technical Representative

• Knowledge Network

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

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 in order 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.

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 "NOTICE" 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 guideline 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 relief valve is collected and stored. Data from testing components is used in order to compare values. Always compare data that is collected from the same valve group that is being tested. Records for the valve groups 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

Test Bench (Requirements)

A Caterpillar Hydraulic Test Center was used to develop the test procedures that are contained in this publication. Not all hydraulic test benches can duplicate the conditions that are contained in this procedure. Make sure that your test bench can properly test the component.

Torque Converter Inlet Relief Valve

Installation Procedure

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Illustration 3	g00930804

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Illustration 4	g00930805

1. Install the torque converter inlet relief valve on Tooling (A).

   Note: The O-ring seal must be installed on the torque converter inlet relief valve.

2. Tighten the mounting bolts to a torque of 70 ± 15 N·m (55 ± 11 lb ft) according to the sequence in Illustration 4.
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   Illustration 5	g00930807
   (1) Supply Oil Inlet (2) Oil Outlet

3. Connect hose assembly (1) to Tooling (A).
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   Illustration 6	g00987487
   "Main Pump Test Port S5"

4. Connect hose assembly (1) to the test bench.

5. Connect hose assembly (2) to Tooling (A).

   Note: Hose assembly (2) will drain into the test bench bed.

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   Illustration 7	g00930808

6. Install Tooling (C).
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   Illustration 8	g00930810

7. Remove cover (3).

Test Procedure

Note: The torque converter inlet relief valve must be tested before the torque converter can be tested.

Note: Refer to Specifications, RENR2605, "797 Off-Highway Truck Power Train", Systems Operation, RENR2606, "797 Off-Highway Truck Power Train", or Systems Operation, RENR2607, "797 Off-Highway Truck Power Train" for additional information.

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Illustration 9	g00930811

1. Open the valve on Tooling (A).

   Note: There must be 0 kPa (0 psi) back pressure.

2. Adjust the supply flow rate to 34 ± 4 L/min (9 ± 1 US gpm).
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   Illustration 10	g00930813

3. Rotate setscrew (4) to adjust the supply pressure. The correct supply pressure is 896 ± 34 kPa (130 ± 5 psi).

4. Make sure that the supply flow rate is 34 ± 4 L/min (9 ± 1 US gpm). If necessary, repeat Steps 2 through 5.

5. Record the serial number and the data in Table 5.

6. Install cover (3).

Torque Converter Outlet Relief Valve

Installation Procedure

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Illustration 11	g00930804

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Illustration 12	g00931148

1. Install the torque converter outlet relief valve on Tooling (A).

   Note: The O-ring seal must be installed on the torque converter outlet relief valve.

2. Tighten the mounting bolts to a torque of 70 ± 15 N·m (55 ± 11 lb ft) according to the sequence in Illustration 12.
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   Illustration 13	g00930807
   (1) Supply Oil Inlet (2) Oil Outlet

3. Connect hose assembly (1) to Tooling (A).
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   Illustration 14	g00987487
   "Main Pump Test Port S5"

4. Connect hose assembly (1) to the test bench.

5. Connect hose assembly (2) to Tooling (A).

   Note: Hose assembly (2) will drain into the test bench bed.

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   Illustration 15	g00930808

6. Install Tooling (C).
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   Illustration 16	g00930810

7. Remove cover (3).

Test Procedure

Note: The torque converter outlet relief valve must be tested before the torque converter can be tested.

Note: Refer to Specifications, RENR2605, "797 Off-Highway Truck Power Train", Systems Operation, RENR2606, "797 Off-Highway Truck Power Train", or Systems Operation, RENR2607, "797 Off-Highway Truck Power Train" for additional information.

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Illustration 17	g00930811

1. Open the valve on Tooling (A).

2. Adjust the supply flow rate to 322 ± 4 L/min (85 ± 1 US gpm).
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   Illustration 18	g00930811

3. Adjust the valve to set the back pressure to 165 kPa (24 psi).
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   Illustration 19	g00930813

4. Rotate setscrew (4) to adjust the supply pressure. The correct supply pressure is 283 ± 21 kPa (41 ± 3 psi).

5. Record the serial number and the data in Table 6.

6. Install cover (3).

Transmission Main Relief Valve

Installation Procedure

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Illustration 20	g00930821

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Illustration 21	g00931151

1. Install the transmission main relief valve on Tooling (A).

2. Tighten the mounting bolts to a torque of 25 ± 6 N·m (18 ± 4 lb ft) according to the sequence in Illustration 21.
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   Illustration 22	g00930825
   (1) Supply Oil Inlet (2) Oil Outlet

3. Connect hose assembly (1) to Tooling (B).
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   Illustration 23	g00987487
   "Main Pump Test Port S5"

4. Connect hose assembly (1) to the test bench.

5. Connect hose assembly (2) to Tooling (B).

   Note: Hose assembly (2) will drain into the test bench bed.

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   Illustration 24	g00930826

6. Install Tooling (C).
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   Illustration 25	g00930810

7. Remove cover (3).

Test Procedure

Note: The transmission main relief valve must be tested before the transmission can be tested. The transmission main relief valve can only be adjusted on the test bench. The transmission main relief valve cannot be adjusted on the transmission.

Note: Refer to Specifications, RENR2605, "797 Off-Highway Truck Power Train", Systems Operation, RENR2606, "797 Off-Highway Truck Power Train", or Systems Operation, RENR2607, "797 Off-Highway Truck Power Train" for additional information.

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Illustration 26	g00930827

1. Open the valve on Tooling (A).

   Note: There must be 0 kPa (0 psi) back pressure.

2. Adjust the supply flow rate to 307 ± 4 L/min (81 ± 1 US gpm).
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   Illustration 27	g00930827

3. Adjust the valve to set the back pressure to 896 ± 34 kPa (130 ± 5 psi).
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   Illustration 28	g00930813

4. Rotate setscrew (4) to adjust the supply pressure. The correct supply pressure is 2586 ± 34 kPa (375 ± 5 psi).

5. Record the serial number and the data in Table 7.

6. Install cover (3).

Relief Valve Bench Test Data Sheet

Torque Converter Inlet Relief Valve

Torque Converter Outlet Relief Valve

Transmission Main Relief Valve

Contamination Control