- Off-Highway Truck/Tractor:
- 73D (S/N: 9YS1-UP; 1GW1-UP)
- 772 (S/N: 10S1-UP)
- 772B (S/N: 64W1-UP)
- 773B (S/N: 5SC1-UP; 63W1-UP)
- 773D (S/N: NBJ1-UP; BGL1-UP; 7ER1-UP; 7CS1-UP)
- 773E Series 2 (S/N: PRB1-UP)
- 773E (S/N: BDA1-UP; KEG1-UP; ASK1-UP)
- 773F (S/N: EED1-UP; EXD1-UP)
- 772 (S/N: 10S1-UP)
- Quarry Truck:
- 773G (S/N: MWH1-UP; JWS1-UP; T5S1-UP; G731-UP)
- 775B (S/N: 7XJ1-UP)
- 775D (S/N: 6KR1-UP; 8AS1-UP)
- 775E (S/N: BEC1-UP)
- 775F (S/N: EYG1-UP; DLS1-UP)
- 775G (S/N: RFM1-UP; MJS1-UP; T5W1-UP)
- 775B (S/N: 7XJ1-UP)
- Wheel Loader:
- 988B (S/N: 50W1-UP)
- 992C (S/N: 49Z1-UP)
- 992D (S/N: 7MJ1-UP)
- 992C (S/N: 49Z1-UP)
Introduction
| Revision | Summary of Changes in REHS3459 | |
| 05 | Added serial number prefixes and new machine models. Standardized. |
|
| 04 | Added "Think Safety" graphic. | |
| 03 | Updated Introduction. Updated Table 4. |
|
| 02 | Updated introduction and added Canceled Part Numbers section. | |
© 2015 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
- Dealer Solution Network
- Cat Technical Representative
- Knowledge Network
| Machine Model | Torque Converter Arrangement |
| 73D, 772, 772B, 773B, 773D, 773E, 773F | 227-8189 |
| 773G, 775B, 775D, 775E, 775F, 775G | 227-8189 |
| 988B, 992C, 992D | 227-8189 |
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 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 | 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) | 8 | |
| 5P-8245 | Hard Washer | 8 | |
| E | 439-3939 | Link Bracket | 2 |
| 7X-0343 | Bolt (5/8-11x1.25 inch) | 2 | |
| 8T-4122 | Hard Washer | 2 | |
| F | 1U-6721 | Adapter Assembly | 1 |
| G | 1U-9131 | Adapter (1) | 1 |
| H | 1U-9359 | Adapter (2) | 1 |
| J | 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-1595 | Bolt (1/2-13X1.25 inch) | 4 | |
| K | 222-1110 | O-Ring Seal | 1 |
| 1U-9870 | Flange | 1 | |
| 5S-2256 | Bolt (1/2-13X1.75 inch) | 4 | |
| 6F-7732 | Reducer Bushing | 1 | |
| 004-5703 | Pipe Adapter | 1 | |
| 005-8615 | Nipple (Pipe) | 2 | |
| 3B-6555 | Elbow | 1 | |
| 6B-5072 | Reducer Bushing | 2 | |
| 6V-3966 | Nipple (Quick Disconnect) | 2 | |
| 120-6843 | Ball Valve | 1 | |
| 4B-7770 | Tee (Pipe) | 2 | |
| 1L-4031 | Tee | 1 | |
| 8C-9024 | Nipple (Quick Disconnect) | 1 | |
| 061-9593 | Reducer Bushing | 1 | |
| 3B-6555 | Fitting | 2 | |
| L | 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 | |
| M | 8C-7313 | Adapter | 1 |
| N | 277-2362 | Transmission Analyzer III Gp | 1 |
| 9U-7496 | 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) .
 | |
| Illustration 3 | g01333200 |
- Install Tooling (B) to Tooling (A) .
 | |
| Illustration 4 | g01333201 |
- use a hoist to install Tooling (C) to Tooling (A). The weight of Tooling (C) is 113.4 kg (250.0 lb).
 | |
| Illustration 5 | g01333203 |
- Install Tooling (D) .
 | |
| Illustration 6 | g01333208 |
- Install Tooling (E) .
 | |
| Illustration 7 | g01333207 |
- Use a hoist to install the torque converter on Tooling (B) .
 | |
| Illustration 8 | g01333205 |
- Tighten the collet on Tooling (C) 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 9 | g01333215 |
- Install Tooling (F) to Tooling (C) .
 | |
| Illustration 10 | g01333217 |
- 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 11 | g01333218 |
- Align the torque converter with the input drive shaft.
 | |
| Illustration 12 | g01333219 |
- Connect the drive shaft to Tooling (G) .
- Install the drive shaft guard.
 | |
| Illustration 13 | g01333220 |
- Remove filter assembly (1) .
 | |
| Illustration 14 | g01333358 |
- Install Tooling (J) .
 | |
| Illustration 15 | g01333359 |
- Install Tooling (K) .
 | |
| Illustration 16 | g01333360 |
- Install Tooling (L) to Tooling (K) .
 | |
| Illustration 17 | g01333362 |
- Install Tooling (M) .
 | |
| Illustration 18 | g01333363 |
- Connect Hose Assembly (2) from the main pump flow (flow meter out) to Tooling (K) .
 | |
| Illustration 19 | g01333395 |
(2) Supply Oil | |
- Connect Hose Assembly (3) from Tooling (J) to the inlet of the "Number 2" flow meter.
 | |
| Illustration 20 | g01333397 |
(3) Torque Converter Outlet | |
- Connect Hose Assembly (4) from the outlet of the "Number 2" flow meter to the oil drain.
 | |
| Illustration 21 | g01333399 |
- Connect Hose Assembly (5) from Tooling (L) to Tooling (M) .
 | |
| Illustration 22 | g01333398 |
(5) Lockup Clutch Supply | |
- Connect lubrication line (6) from the test bench to Tooling (C). Maintain an oil pressure of 275.8 kPa (40.0 psi).
 | |
| Illustration 23 | g01333495 |
(6) Spindle Lubrication Oil Supply | |
- Connect pressure gauge (7) to Tooling (K), as shown.
 | |
| Illustration 24 | g01333417 |
(7) Supply Pressure | |
- Connect pressure gauge (8) to Tooling (K), as shown.
 | |
| Illustration 25 | g01333418 |
(8) Torque Converter Inlet Pressure | |
- Connect a pressure gauge to test port (9) .
 | |
| Illustration 26 | g01333419 |
(9) Outlet Relief Valve Pressure | |
- Connect a pressure gauge to test port (10) .
 | |
| Illustration 27 | g01333420 |
(10) Lockup Clutch Pressure | |
- Install Tooling (N).
Note: Refer to Tool Operating Manual, NEHS0966 for the correct operating instructions.
 | |
| Illustration 28 | g01333415 |
Tooling (N) | |
 | |
| Illustration 29 | g01333421 |
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 (K) counterclockwise to remove restriction in the inlet flow.
- Adjust the main pump flow to 151.4 L/min (40.0 US gpm).
- Adjust Tooling (K) clockwise to increase supply pressure to 1379.0 ± 34.5 kPa (200 ± 5 psi).
- Readjust the main pump flow to 151.4 L/min (40.0 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 30 | g02720621 |
- Maintain input speed, oil flow, and pressure for 5 minutes to purge air from the system.
Torque Converter Pressure and Leakage Test
- Adjust Tooling (K) counterclockwise to remove restriction in the inlet flow.
- Adjust the main pump flow to 151.4 L/min (40.0 US gpm).
- Adjust Tooling (K) clockwise in order to increase supply pressure to 1379.0 ± 34.5 kPa (200 ± 5 psi).
- Readjust the main pump flow to 151.4 L/min (40.0 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 pressure in Table 6.
- Record the torque converter outlet relief pressure in Table 6.
- Record the torque converter outlet flow in Table 6.
- To obtain leakage, subtract the output flow from the input flow.
- Record the calculation in Table 6.
Lockup Clutch Test
- Adjust Tooling (K) counterclockwise to remove restriction in the inlet flow.
- Adjust the main pump flow to 151.4 L/min (40.0 US gpm).
- Adjust Tooling (K) clockwise to increase supply pressure to 1379.0 ± 34.5 kPa (200 ± 5 psi).
- Readjust the main pump flow to 151.4 L/min (40.0 US gpm).
- Adjust the input rotation to 1400 ± 10 rpm.
- Use Tooling (N) to engage the lockup clutch.
- Record lockup clutch pressure in Table 7.
- Record the lockup clutch leakage in Table 7.
- Use Tooling (N) 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 8.
- Remove the torque converter from the test bench if the test bench oil supply is within specifications.
Torque Converter Bench Test Data Sheet
| CATERPILLAR | Torque Converter Bench Test Data Sheet | Test Date:_______ |
| Model:_______ | ||
| Work Order:___________ | Serial No.:_______ | |
Specifications
| General Specifications | |
| Input Speed | 1400 ± 10 rpm |
| Supply Pressure | 1379.0 ± 34.5 kPa (200.0 ± 5.0 psi) |
| Torque Converter Inlet Flow | 181.8 L/min (40.0 US gpm) |
| Torque Converter Outlet Flow | 170.4 ± 11.4 L/min (37.5 US ± 2.5 gpm) |
| Maximum Torque Converter Leakage | 19.0 L/min (5.0 US gpm) |
| Torque Converter Inlet Pressure | 620.5 ± 69.0 kPa (90.0 ± 10.0 psi) |
| Outlet Relief Valve Pressure | 551.6 ± 69.0 kPa (80.0 ± 10.0 psi) |
| Lockup Clutch Supply Pressure | 1310.0 ± 34.5 kPa (190.0 ± 5.0 psi) |
| Maximum Lockup Clutch Leakage | 6.1 L/min (1.6 US gpm) |
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 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 |
Lockup Clutch Test
| Torque Converter Lockup Clutch | ||
| Input Speed (1400 ± 5 rpm) Output Flow 151.4 L/min (40.0 US gpm) Supply Pressure 1379.0 ± 34.5 kPa (200.0 ± 5.0 psi) |
Lockup Clutch Pressure (1) | _______kPa _______(psi) |
| Lockup Clutch Leakage (2) | _______L/Min _______(gpm) |
|
| ( 1 ) | The Lockup Clutch Pressure is measured at pressure gauge (10) . |
| ( 2 ) | The Lockup Clutch Leakage is measured at Tooling (L) . |
Contamination Control
| ISO Particle Count | Sample the test bench oil supply. |
________/________Particle Count |
| ______________________________________ Technician |
______________________________________ Supervisor |