Turbine Wheel for Torque Converters Used with Power Shift Transmissions {3101, 3131} Caterpillar

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Introduction

© 2018 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 Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made 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 Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) Interface.

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

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

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 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.

Service Letters and Technical Information Bulletins

Welder Qualifications

Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a respirator for breathing protection.

Welders must be qualified for the appropriate type of weld that is being performed. Shielded Metal Arc Welding (SMAW) or Flux Cored Arc Welding (FCAW). Qualifications should be in accordance with ANSI/AWS D1.1, D14.3, or Caterpillar Manufacturing Practice MC1000-105. Welders must be qualified for the appropriate position of weld that is being performed. Refer to AWS Specifications D1.1 and D14.3 or comparable standards for information that regards qualification requirements. The welders must have used the process at some time within the last 6 months. The welders must complete the process of certification if the welders have not used the welding processes for 6 months. The welding operator must hold a current certification for this process.

References

Tooling and Equipment

Table 3 contains the items that are needed to complete the repair procedures in this guideline.

Prepare the Area for Inspection and Welding

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Personal injury can result when using cleaner solvents. To help prevent personal injury, follow the instructions and warnings on the cleaner solvent container before using.

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Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

Illustration 3	g03721203
Typical burr removal tooling. (A) Right Angle Die Grinder (B) Die Grinder (C) ( D) ( E) Conditioning Discs, Disc Pad Holder, and Threaded Shaft (F) ( G) Flapper Wheels

• Clean all surfaces for inspection before you inspect the part. Make sure that you remove all debris, paint, and oil.

• When you move parts that require cleaning, always use a proper lifting device. This device must protect the part from damage. For the safety of the operator, all lifting devices must be inspected before use.

• During cleaning, do not damage machined surfaces.

• Use pressurized air to dry parts.

Preheat the base metal to a minimum of 21 °C (70 °F). Maintain the minimum temperature throughout the welding process.

Clean the area that will be welded. Make sure that the substances that follow are removed from the area that will be welded.

• Oil

• Grease

• Paint

• Dirt

Summary

Typical example of the turbine wheel

Illustration 4	g02093455
(1) Inside diameter (2) Fins (3) Outside diameter (4) Spline

Illustration 5	g02096877
Type A turbine wheel (5) Wear area (6) Splines (D) Outside diameter (E) Inside diameter

Illustration 6	g02096913
Type B turbine wheel (5) Wear area (6) Splines (D) Outside diameter (E) Inside diameter

Illustration 7	g03315177
Type C turbine wheel (5) Wear area (D) Outside diameter (E) Inside diameter (F) Pilot bore

The areas that must be checked to see if the turbine wheels can be used again are:

• The splines for wear (type A turbines).

• The fins for damage (all types).

• The clearance between the turbine wheel and the stator (type A turbines).

• Both ends of the hub for wear (type A turbines).

Spline Wear

The 1T-0221 Turbine Wheel cannot be used again if the spline teeth are worn too much. Use a flexible ruler to measure the tip width on the top and bottom of three spline teeth, 120 degrees apart as shown in Illustration 8.

Illustration 8	g02098273
(G) Measure the width of the spline teeth (H) Measure the top and bottom of the spline for wear

Do not use a 1T-0221 Turbine Wheel whose width is less than the use again minimum width as shown in Table 4

For 1T0-020, 1T0-052, 1T1-909, 1T1-994, 1T1-993, 1T0-079, 1T1-801, 1T1-805, 1T1-609, 1T-0842 Turbine Wheel, put the turbine wheel on the drive flange splines. These turbine wheels must fit on the splines of the drive flange with no obvious (easily felt) looseness.

Fin Damage

Do not use any turbine wheel that has cracks in the fins. Most fin cracks will be on the inside circumference as shown in Illustration 9. However, the fins should also be checked on the outside circumference.

Illustration 9	g02098357

(7) Do not use again. Turbine wheel has cracks in the fin.

Clearance Between Stator and Turbine Wheel

Failure or normal wear of bearings and splines in a torque converter eventually causes contact and wear of the seal (inside) bore and outside diameter of the turbine wheel.

Measure Running Clearance

The running clearance between the stator wheel and the turbine wheel for type A turbines must be limited if the torque converter is to operate with efficiency. Refer to Illustration 10 for the running clearance (J).

Illustration 10	g02098358
(J) Measure running clearance

Before the running clearance is measured, check the turbine wheel for a lip on the inside circumference. Use a machinist scraper or file to remove this lip refer to Illustration 11. If this lip is not removed, the running clearance cannot be measured with accuracy.

Illustration 11	g02098373
Remove any lip from the inside circumference of the turbine wheel.

Use the following procedure to measure the running clearance between the stator wheel and the turbine wheel.

1. Put four steel balls in the turbine wheel approximately 90 degrees apart as shown in Illustration 12. Refer to Table 5 for steel ball part numbers and diameter.
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   Table 5

   Turbine Wheel Part Number	Ball Part Number	Ball Diameter
   1T-0020, 1T-0842, 1T-1801, 1T-1805, 1T-1609	2D-6642	6.3500 ± 0.0002 mm (0.2500 ± 0.000 inch)
   1T-0052, 1T-1909, 1T-1994, 1T-1993, 1T-0079	1M-6718	3.965 ± 0.013 mm (0.1562 ± 0.0005 inch)
   1T-0221	4B-9880	7.938 ± 0.005 mm (0.3125 ± 0.0002 inch)

2. Put the stator that is used with the turbine in position on the balls as shown in Illustration 12. Make sure that the balls do not move. Turn the stator until the flat surface of the turbine wheel is against the balls.

3. Install an 8T-5096 Dial Indicator Gp on the turbine wheel as shown in Illustration 13. Move the stator toward the stem of the dial indicator until the outside diameter is against the inside diameter of the turbine wheel. Move the stem of the dial indicator against the stator. Put the dial indicator on zero.

4. Push the stator away from the stem of the dial indicator until the stator outside diameter is in contact with the opposite inside diameter of the turbine wheel. Measure the clearance. Make this measurement at four points, 45 degrees apart, around the turbine wheel. Do not use the turbine wheel again if the measurement is more than 0.76 mm (0.030 inch).

Illustration 12	g02098413
Preparation to check running clearance (K) Outside diameter of the stator (L) Inside diameter of the turbine wheel (8) Stator (9) Steel balls (10) Turbine wheel

Illustration 13	g02100036
Measure the clearance with a dial indicator. (11) 8T-5096 Dial Indicator Gp

Salvage Procedures

Turbine wheels with excessive wear can be reused after the inside and outside circumferences are built up with metal spray.

The surfaces to be built up must be clean. Degrease and wire brush the surfaces to remove all contaminants.

1. Use either Step 1.a or Step 1.b to build up the turbine wheel.

   1. Build up the worn bore and outside diameter with a MIG welder using 0.76 mm (0.030 inch) diameter or 1.14 mm (0.045 inch) diameter AWS ER4043 wire. Use Argon shield gas at 1.0 cmh (35 cfh) to minimize heat input and penetration. Set the wire feed speed to 150-170 mm per second (350-400 inches per minute), and set the voltage to 19-22 V.

   2. Metal spray is an acceptable method of restoring a surface to the original size. Consult the manufacturer of the metal spray equipment for powder recommendations, machine settings, and application procedures. Each step in the procedure is critical in achieving the desired coating bond and finish.

      Note: Sulzer Metco Inc. is one manufacturer of acceptable metal spraying equipment and powder. A list of Sulzer Metco Inc. sales offices is at the back of Guideline For Reusable Parts - Repair of Transmission, SEBF8060, "Repair of Transmission, Torque Converter and Torque Divider Shafts".

2. Next, machine the diameter to size:

   1. Secure the turbine in a lathe. Check with an indicator to ensure the mounting bore spline teeth (type A and type B turbines - see Illustration 5 and Illustration 6) or the mounting flange pilot bore (type C turbines - see Illustration 7) are within 0.10 mm (0.004 inch) total indicator reading.

   2. Turn the inside diameter (seal bore) and outside diameter to specifications shown in Table 6.

      Note: Be sure that no weld or metal spray is protruding into the oil flow paths. Any material that does protrude into the flow paths causes a reduction of converter efficiency.

Hub Wear

Refer to Illustration 14 that shows a cross section view of a type A turbine wheel. Measure dimensions (M) and (N) to see if the turbine wheel can be used again.

Illustration 14	g02100093
Turbine wheel

Illustration 15	g02100154
Measurement of dimension (M)

1. Two people are needed to measure Dimension (M). One person holds a rigid 150 mm (5.9 inch) steel ruler. The other person uses a depth micrometer.

2. Put the straight edge of the ruler on face (12) of the turbine wheel as shown in Illustration 15. Use both hands to hold the ruler firmly (without movement) against face (12). Point the other end of the ruler toward the hub, but do not allow the ruler to touch the curved surface of the turbine wheel.

3. Use a depth micrometer to measure dimension (M) from face (13) to the straight edge of the ruler as shown in Illustration 15. Be sure the base of the micrometer is held firmly against face (13).

4. If dimension (M) is greater than or equal to the minimum dimension given in Table 7, go to Step 5. If dimension (M) is less than the minimum dimension, machine face (13) until dimension (M) equals machined dimension (M) as shown in Table 7. Make a spacer from SAE 1020 steel that is 3.180 ± 0.080 mm (0.1252 ± 0.0032 inch) thick and has the outer and inner diameters shown in Table 7. The sides of the spacer must be parallel within 0.08 mm (0.003 inch).

5. Measure dimension (N) with a micrometer. If a spacer was made in Step 5, place the spacer on the end of the hub when measuring dimension (N).

6. If dimension (N) as measured in Step 5 is equal to or greater than the minimum dimension given in Table 8, the turbine wheel can be used again. If dimension (N) is less than the minimum dimension, machine face (14) until dimension (N) equals the machined dimension (N) shown in Table 8. Make a spacer from SAE 1020 steel that is 3.180 ± 0.080 mm (0.1252 ± 0.0032 inch). The sides of the spacer must be parallel within 0.08 mm (0.003 inch).

   Note: The 1T-0221 Turbine Wheel has oil slots on each end of the hub that are 12.7 mm (0.50 inch) wide and 3.0 mm (0.12 inch) deep. Machine new slots in the ends of the hub as needed.

7. Assemble the turbine wheel spacers as needed.