Bench Test Procedure For A D8R Track-Type Tractor Torque Converter{3101} Caterpillar

Track-Type Tractor:

D8R (S/N: 7XM1-UP; 9EM1-UP)

Introduction

© 2011 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar 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. 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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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.

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.

Installation Procedure

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Illustration 1	g01400884

1. Install Tooling (A) .

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Illustration 2	g01400887

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

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Illustration 3	g01400889

3. Tooling (C) .

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Illustration 4	g01400908

4. Install Tooling (D) to Tooling (C) .

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Illustration 5	g01400913

5. Install Tooling (E) to Tooling (C) .

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Illustration 6	g01400914

6. Install Tooling (F) in order to retain Tooling (E) .

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Illustration 7	g01400916

7. Install Tooling (C) to the torque converter.

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Illustration 8	g01400965

8. Install Tooling (G) .

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Illustration 9	g01400853

9. Install Tooling (H) .

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Illustration 10	g01400974

10. Use a hoist to install the torque converter on the test bench. The weight of the torque converter is 181.5 kg (400.0 lb).

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Illustration 11	g01400855

11. Use Tooling (J) in order to secure the torque converter to the test bench.

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Illustration 12	g01401006

12. Tighten the collet on Tooling (G) in order to connect Tooling (G) 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 13	g01401010

13. Install Tooling (K) to Tooling (G) .

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Illustration 14	g01401014

14. Install Tooling (L) to Tooling (K) .

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

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Illustration 15	g01401016

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

16. Connect the input drive shaft to Tooling (L) .

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Illustration 16	g01401019

17. Install the drive shaft guard.

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Illustration 17	g01400871

18. Install Tooling (N) .

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Illustration 18	g01400861

19. Remove cover plate (1) .

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Illustration 19	g01400873

20. Install Tooling (P) .

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Illustration 20	g01400875

21. Connect hose assembly (2) from the outlet of the pressurized flow meter to Tooling (N) .

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Illustration 21	g01400876

22. Connect hose assembly (3) from the inlet of the No. 2 flow meter to Tooling (P) .

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Illustration 22	g01401041

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

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Illustration 23	g01401048
(5) Spindle Lubrication Oil Supply

24. Connect lube line (6) from the test bench to Tooling (G). Maintain an oil pressure of 275 kPa (40 psi).

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Illustration 24	g01400880
(6) Torque Converter Inlet Pressure

25. Connect pressure gauge (6) to Tooling (N) .

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Illustration 25	g01400883
(7) Torque Converter Outlet Relief Pressure

26. Connect pressure gauge (7) to Tooling (Q) .

Test Procedure

Warm-up Procedure

1. 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.

2. Adjust the output flow at the No. 2 flow meter to 106 ± 1.9 L (28.0 ± .50 US gal).

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Illustration 26	g01401060

3. Rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 ± 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

1. Adjust the output flow at the No. 2 flow meter to 106 ± 1.9 L (28.0 ± .50 US gal).

2. Adjust the input rotation to 1600 ± 20 rpm.

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

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

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

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

7. Record the calculation in Table 6.

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 7.

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

Specifications

Torque Converter Bench Test Data Sheet

Torque Converter Leakage

Contamination Control