Bench Test Procedure For A 784B, 784C, 785B, 785C, and 785D Off-Highway Truck Torque Converter{3101} Caterpillar


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Bench Test Procedure For A 784B, 784C, 785B, 785C, and 785D Off-Highway Truck Torque Converter{3101} [REHS3463]
POWER TRAIN
TORQUE CONVERTER GP
Bench Test Procedure For A 784B, 784C, 785B, 785C, and 785D Off-Highway Truck Torque Converter{3101}
1.1. Introduction
2.1. Canceled Part Numbers and Replaced Part Numbers
3.1. Collecting The Test Data
4.1. Tools Needed
5.1. Installation Procedure
6.1. Test Procedure
7.2. Start Checks
8.2. Warm-up Procedure
9.2. Torque Converter Leakage and Lockup Clutch Pilot Pressure
10.2. Torque Converter Inlet Relief Valve Test
11.2. Lockup Clutch Test
12.2. Lockup Clutch Primary Pressure
13.2. Contamination Control
14.1. Specifications
15.1. Torque Converter Bench Test Data Sheet
16.2. Torque Converter Leakage
17.2. Torque Converter Lockup Clutch Pilot Pressure
18.2. Torque Converter Inlet Relief Valve Test
19.2. Torque Converter Lockup Clutch Pressure
20.2. Lockup Clutch Primary Pressure
21.2. Contamination Control
Off-Highway Truck/Tractor:
784B (S/N: 5RK1-UP)
784C (S/N: 2PZ1-UP)
785B (S/N: 6HK1-UP)
785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)
785D (S/N: DMC1-UP; MSY1-UP)

Introduction

Table 1
Revision     Summary of Changes in REHS3463    
01     Added new introduction, Canceled Part Numbers section, and updated effectivity.    

© 2011 AVSpare 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 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. Testing 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 AVSpare. 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 AVSpare.

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 AVSpare Repair Process Engineering:

  • AVSpare Dealer Technical Communicator

  • Dealer Solution Network

  • AVSpare Technical Representative

  • Knowledge Network

Table 2
Machine Model     Torque Converter Arrangement    
784B     117-3357    
784C     117-3357    
785B     117-3357    
785C     117-3357    
785D     117-3357    

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 torque converter is collected and stored. Averages from each torque converter arrangement are often used in order to compare values on portions of torque converter tests. Always compare data that is collected from the same torque converter arrangement that is being tested. Averages for the last 20 torque converter arrangements should be maintained.

------ WARNING! ------

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.

----------------------

------ WARNING! ------

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

----------------------

------ WARNING! ------

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.

Table 3
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     6V-3965     Nipple (Quick Disconnect)     1    
U     1U-6392     Valve (Pressure Rglt)     1    
6V-3966 Fitting As     6    
6V-3965 Fitting As     2    
8T-0856 Gauge (Pressure)     2    
6V-4144 Coupler As     2    
2D-7325 Tee     2    
( 1 ) Parker - Hannifin Identification Number

Installation Procedure




    Illustration 1g01411904

  1. Install Tooling (A) .



    Illustration 2g01411899

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



    Illustration 3g01291592

  1. Install Tooling (C) .



    Illustration 4g01411917

  1. Remove pump (1) .



    Illustration 5g01411921

  1. Remove plug (2) .



    Illustration 6g01411918

  1. Remove magnetic filter (3) .



    Illustration 7g01411396

  1. Install Tooling (D) .



    Illustration 8g01411931

  1. Install Tooling (E) .



    Illustration 9g01411932

  1. 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 10g01411936

  1. Use Tooling (F) in order to secure the torque converter to Tooling (B) .



    Illustration 11g01291616

  1. 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 12g01291622

  1. Install Tooling (G) .



    Illustration 13g01291642

  1. 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 14g01291645

  1. Align the torque converter with the drive shaft.

  1. Connect the drive shaft to Tooling (H) .



    Illustration 15g01291648

  1. Install the drive shaft guard.



    Illustration 16g01411402

  1. Install Tooling (K) .



    Illustration 17g01412184

  1. Install Tooling (L) .



    Illustration 18g01411413

  1. Install Tooling (M) .



    Illustration 19g01411418

  1. Remove plug (4) .



    Illustration 20g01411421

  1. Install Tooling (N) .



    Illustration 21g01411423

  1. Remove plug (5) .



    Illustration 22g01411427

  1. Install Tooling (O) .



    Illustration 23g01411430

  1. Remove plug (6) .



    Illustration 24g01411431

  1. Install Tooling (P) .



    Illustration 25g01411433

  1. Remove plug (7) .



    Illustration 26g01411435

  1. Install Tooling (Q) .



    Illustration 27g01412187

  1. Remove plug (8) .



    Illustration 28g01411437

  1. Install Tooling (R) .



    Illustration 29g01411438

  1. Remove plug (9) .



    Illustration 30g01411440

  1. Install Tooling (S) .



    Illustration 31g01412192

  1. Remove plug (10) .



    Illustration 32g01411441

  1. Install Tooling (T) .



    Illustration 33g01411442

    (11) Supply Oil

  1. Connect hose assembly (11) from the pressurized flow meter to Tooling (K) .



    Illustration 34g01411444

    (12) Torque Converter Outlet Flow

  1. Connect hose assembly (12) from Tooling (M) to the inlet of the No. 2 flow meter.



    Illustration 35g01412792

    (13) Return To Sump

  1. Connect hose assembly (13) from the outlet of the No. 2 flow meter to the test bench sump.



    Illustration 36g01411452



    Illustration 37g01411706

    (14) Lockup Clutch Oil Supply

  1. Connect hose assembly (14) from Tooling (L) to Tooling (Q) .



    Illustration 38g01411709

    (15) Spindle Lubrication

  1. Connect lube line (15) from the test bench to Tooling (C). Maintain an oil pressure of 275.8 kPa (40 psi).



    Illustration 39g01411714

    (16) Lockup Clutch Control Supply




    Illustration 40g01411726

  1. Connect hose assembly (16) from Tooling (K) to the inlet of Tooling (U) .



    Illustration 41g01411734



    Illustration 42g01411940

    (17) Lockup Clutch Signal Supply

  1. Connect hose assembly (17) from the outlet of Tooling (U) to Tooling (S) .



    Illustration 43g01411730

    (18) Pressure Reducing Valve Drain

  1. Connect hose assembly (18) from Tooling (U) to the drain.



    Illustration 44g01411943

    (19) Lockup Clutch Signal Pressure

  1. Connect pressure gauge (19) to Tooling (T) .



    Illustration 45g01411720

    (20) Torque Converter Inlet Relief Pressure

  1. Connect pressure gauge (20) to Tooling (N) .



    Illustration 46g01411941

    (21) Torque Converter Outlet Relief Pressure

  1. Connect pressure gauge (21) to Tooling (O) .



    Illustration 47g01411945

    (22) Lockup Clutch Pilot Pressure

  1. Connect pressure gauge (22) .



    Illustration 48g01411946

    (23) Lockup Clutch Pressure

  1. Connect pressure gauge (23) to Tooling (R) .

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, SENR6307, "784B and 785B Off-Highway Truck/Tractors Power Train" or Testing and Adjusting, SENR1489, "784C and 785C Off-Highway Truck/Tractors Power Train" for additional information.

Start Checks

Table 4
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

  1. Begin using SAE 10W hydraulic oil. Warm the oil to 50 °C (125 °F). Maintain this temperature for the duration of the test.

  1. Turn on the knob Tooling (K) counterclockwise in order to remove any restriction to the inlet flow.

  1. Adjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).

  1. Adjust Tooling (K) clockwise in order to increase the supply pressure to 3447.4 ± 68.9 kPa (500 ± 10 psi).

  1. Readjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).



    Illustration 49g02604480

  1. Rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1300 ± 10 rpm.

  1. 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

  1. Turn on the knob Tooling (K) counterclockwise in order to remove any restriction to the inlet flow.

  1. Adjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).

  1. Adjust Tooling (K) clockwise in order to increase the supply pressure to 3447.4 ± 68.9 kPa (500 ± 10 psi).

  1. Readjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).

  1. Rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1300 ± 10 rpm.

  1. Record the Torque Converter Inlet Flow in Table 7.

  1. Record the Torque Converter Outlet Flow at the No. 2 flow meter in Table 7.

  1. Record the Lockup Clutch Pilot Pressure at pressure gauge (22) in Table 8.

Torque Converter Inlet Relief Valve Test

  1. Turn on the knob Tooling (K) counterclockwise in order to remove any restriction to the inlet flow.

  1. Adjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).

  1. Adjust Tooling (K) clockwise in order to increase the supply pressure to 3447.4 ± 68.9 kPa (500 ± 10 psi).

  1. Readjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).

  1. Rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1300 ± 10 rpm.

  1. 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) .

  1. Record the Torque Converter Inlet Pressure in Table 9. Reference 930.8 ± 34.5 kPa (135.0 ± 5.0 psi)

Lockup Clutch Test

  1. Turn on the knob Tooling (K) counterclockwise in order to remove any restriction to the inlet flow.

  1. Adjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).

  1. Adjust Tooling (K) clockwise in order to increase the supply pressure to 3447.4 ± 68.9 kPa (500 ± 10 psi).

  1. Readjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).

  1. Rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1300 ± 10 rpm.

  1. Adjust Tooling (U) in order to increase the signal pressure at the lockup clutch. The lockup clutch will engage at approximately 1289.3 ± 68.9 kPa (187 ± 10 psi).

  1. Record the supply pressure to the lockup clutch at pressure gauge (23) in Table 10. Reference 2138.0 ± 34.0 kPa (310.0 ± 5.0 psi)

  1. 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).

  1. Adjust Tooling (U) in order to remove all pressure from the Lockup Clutch Signal Supply.

  1. Stop rotation of the torque converter.

  1. Discontinue all oil flow and pressure to the Torque Converter Inlet.

Lockup Clutch Primary Pressure




    Illustration 50g01411951

  1. Remove cover (24) from the Lockup Clutch Valve Group.



    Illustration 51g01411952

  1. Remove load piston plug (25) .



    Illustration 52g01411951

  1. Reinstall cover (24) .

  1. Turn on the knob Tooling (K) counterclockwise in order to remove any restriction to the inlet flow.

  1. Adjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).

  1. Adjust Tooling (K) clockwise in order to increase the supply pressure to 3447.4 ± 68.9 kPa (500 ± 10 psi).

  1. Readjust the inlet flow to 159.0 ± 3.8 L/min (42 ± 1 US gpm).

  1. Rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1300 ± 10 rpm.

  1. Adjust Tooling (U) in order to increase the signal pressure at the lockup clutch. The lockup clutch will engage at approximately 1289.3 ± 68.9 kPa (187 ± 10 psi).

  1. Measure the lockup clutch pressure at Tooling (23) and record the value in Table 11. Reference 1175 ± 35 kPa (170.5 ± 5.0 psi)

  1. Adjust Tooling (U) in order to remove all pressure from the Lockup Clutch Signal Supply.

  1. Stop rotation of the torque converter.

  1. Discontinue all oil flow and pressure to the Torque Converter Inlet.

  1. Remove cover (24) from the Lockup Clutch Valve Group.

  1. Reinstall load piston plug (25) .

  1. Reinstall cover (24) .

Contamination Control

  1. Drain all oil from the torque converter.

  1. Take an oil sample of the test bench oil supply. Oil contamination must be below ISO 16/13.

  1. Record the results in Table 12.

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

Specifications

Table 5
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 Signal Pressure    
1289.3 ± 68.9 kPa (187 ± 10 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

Table 6
AVSpare     Torque Converter Bench Test Data Sheet     Test Date:    
Models: 784B, 784C, 785B, 785C, 785D
Work Order:     Serial No.:    

Torque Converter Leakage

Table 7
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

Table 8
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 (22) .

Torque Converter Inlet Relief Valve Test

Table 9
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 (20) .

Torque Converter Lockup Clutch Pressure

Table 10
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 (23) .
( 2 ) The Lockup Clutch Leakage is measured at Tooling (L) .

Lockup Clutch Primary Pressure

Table 11
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 (23) .

Contamination Control

Table 12
ISO Particle Count     Sample the test bench oil supply.
   
________/________Particle Count    

Table 13






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