Questions and Answers

GENERAL ISSUES section

III.1: Do I need to buy the complete standard set of equipment ? Which items are essential for successful Torque converter rebuilding ?

Our standard set of equipment consists of: 1) WS 2.2 Dual Gun Welding Stand with MIG+TIG (dual chuck system for precise Torque Converter alignment during the welding process; automated MIG welding process; TIG mode for precise and pinpoint welding; automated Torque Converter internal clearance algorithm) 2) PB 2.1 Piston Bonder (application of halogen bulbs heating allows economic energy consumption; steel adapter plates contribute to a more affordable price; adapter plates from steel are easy to produce if needed above the standard set that we supply) 3) ATS 2.1 Leak tester (air test stand) 4) PTS 2.1 Preload tester (used for 6HP** converters by ZF; these converters are very popular and PTS 2.1 has become a must-have item for Torque Converter repair workshops) 5) ICS 2.1 End play tool (used to measure internal clearance within a welded Converter) 6) LTK 360 Tooling for lathe machine to accurately cut open Torque Converters. 7) RT 2.1 - Riveter tool to work with DP0/AL4 Converters. 8) BS 2.1 - Torque Converter Balancer stand is used to confirm the final quality to workshop customers. Top professional service centres use balancing machines as part of their process to comply with OEM requirements. 9) ACS 2.1 - Alignment check stand used to check Impeller Hub/Neck or Body runout. This tool is supplementary because its functions can be covered by the dial indicator that is fitted on the welding stand WS 2.2 10) ITK-S - Standard tool kit used during replacement of an Impeller hub.



III.2: What equipment and tools do I need in addition to the Hydra-Torque equipment ?

In addition to our range of equipment rebuilders will require: - A heavy duty lathe for cutting open the torque converter. Due to the size and weight of this item we recommend a customer to source this locally. Our LTK360 kit contains the necessary Faceplate items required. - A quality parts cleaning system. Generally rebuild shops have already made this investment in their normal transmission rebuild business. - Spare parts. The parts required for rebuilding a torque converter are minimal when compared to rebuilding a transmission unit. Most reputable Parts suppliers worldwide stock all the parts required. Our engineers can advise a customer on these requirements too.



III.3: What skills are needed for working on Torque Converter rebuilding equipment ?

Previous experience of working with industrial machinery will certainly contribute to easier and faster understanding of the rebuilding routine. The cut-open procedure for Torque Converters is potentially the most skilled operation and engineering experience is an advantage but not essential. The welding process is simple because the welding procedure is automated. Removing and replacing a worn-out friction lining is a skill that can be easily acquired. The entire process is covered during the hand-on training package conducted at our working facility in Kettering. Free training and introductory advice is given free of charge to our customers.



III.4: What are the gas mixture and welding wire selection for a Hydra-Torque welding stand?

Typically, 80% СО2 / 20% argon. but other mix ratios typical for use in Transmission workshops are also appropriate. The welding wire to be used is the 0.8mm diameter one.



III.5: What are the maximum dimensions for a Torque Converter to be put on the Welding stand WS 2.2?

Max diameter for the welded Converter = 460mm.
Max height of the welded Converter = 280mm.
Max diameter of the clamp in the lower chuck = 50mm.
Max diameter of the clamp in the upper chuck = 125mm.



HYDRA-TEST - VALVE BODY section

II.1: Do I need to buy both a HT-VBT system and a HT-SOL machine ?

HT-VBT Deluxe allows users to test both complete Valve Bodies and individual Solenoids. HT-SOL is designed for high temperature testing of individual Solenoids. The HT-VBT unit can test individual solenoids by ordering part# 20250 Adapter plate and solenoid test blocks that are used with the HT-SOL machine. The ideal situation is of course to operate with both systems as some solenoid faults can be difficult to detect. Good practise is to ensure good solenoid operation prior to testing the complete valve body. The adapter plate was designed for customers starting out on a budget and to help customers understand the advantages without the additional start up costs. As the test blocks are compatible with both systems, they can be used in the HT-SOL machines once customers decide to make the additional investment.



II.2: Does a Hydra-Test Valve Body test machine allow testing of mechatronic units (TCM / TCU / TEHCM)?

During the testing process the HTC-K Controller replaces the TCU by controlling solenoid operation, switching gears and reading pressure and ampere signals. When testing valve bodies that have an embedded TCU (or TEHCM as they are known) we remove the TEHCM from the testing process and use a dedicated harness. Our system is designed to prove the functionality of the valves, valve circuits and solenoids. Adding the TEHCM to this process only makes diagnosis more complicated. There are many tools on the market to prove a working TEHCM. From our experience and contrary to what some companies will have you believe, there is generally numerous versions of the same TEHCM which then frustrates us when one doesn’t communicate. Even if it is able to “shift” the valve body or transmission, when a fault is detected we then remove the TEHCM to eliminate it from the diagnosis process.



II.3: What is the difference between HT-VBT Deluxe “Single Phase - 220vac” and “3 Phase 380vac” options ?

The Deluxe model is now available to operate using a “3 Phase” (380 volt AC) electricity supply. The main advantages of this option are that the Automatic Transmission fluid can reach higher operating temperatures in a shorter time period and the electricity running costs of the machine will be significantly reduced.



II.4: Is there some guidance available on Hydra-Test products?

We live in the digital era and we use its benefits to our advantage. FaceTime, Skype, TeamViewer, WhatsApp allow many ways of receiving guidance on our Automatic Transmission testing and rebuilding machines. We also have Hydra-Test YouTube channel where we upload useful videos about our products. They include subtitles made by us and there’s also an option of instant subtitle translation feature built-in at YouTube.
We always welcome our clients and potential customers to address us with any questions and we'll work together to establish your true requirements.



II.5: What type of ATF should be used our machines ? Do viscosity differences change test results ?

In reality the volume of oil used in the Valve Body during a test will have no adverse effect when mixed with the large quantity of OE oils used on a full fill. We recommend that only basic grade (Dexron III) fluid be used in our machines. This is for two reasons: the machine holds around 70 litres and you are continually adding oil due to the tested VB's filling. The other reason is if a high grade OE/synthetic oil is used it is not uncommon for faults to only show at very high temperatures. As we are capturing master data and testing all under the same conditions it is fair to assume that they should perform the same. This means any fault should show earlier and at lower temperatures.



II.6: There’s a Valve Body test plate or Solenoid test block that I need but it’s not included in your list. How can this be solved ?

We currently have in excess of 80 test plates for our HT-VBT Deluxe and we have more than 30 Solenoid test blocks available for HT-SOL. We have a full time development department dedicated to expanding our range. Should a customer need a particular Valve Body test plate that is crucial to their own business requirements, we will place it as a high priority on our ever expanding list of development projects.



II.7: Do I need to order all test plates and blocks with the machines or it is possible to buy additional items at a later stage ?

It is advisable to start with the most popular Automatic Transmission models and then add more plates and blocks as required or as finances allow. First of all, it will reduce the initial order lead time and make the general investment smaller. Secondly, there is some time period when the user needs to get better acquainted with the technology and operation processes. After the accustomization stage is completed and the implementation of the machines start to increase business, more test blocks and plates for less frequently seen models can be added.



II.8: Cars usually operate around 15 bar. Why does the Hydra-Test Valve Body machine test at different input pressures (System Pressure) ?

It is important to remember that we are using Input pressure (System Pressure) to regulate oil volume to the valve body (not pressure and not flow). By doing this we are simulating different throttle positions or engine RPM. Line pressure of a transmission is typically between 4-20 Bar (minimum to maximum). Each transmission will produce different oil volumes depending upon the design of the pump used and of course the engine RPM. When we first design a Valve Body test plate, we need to know the maximum oil volume required to achieve the highest pressure the Automatic Transmission is capable of producing. This would typically be Stall pressure in Reverse gear. We then close the on/off valve to see the highest setting we need to use. For example, this may be 25 Bar and this would represent a maximum throttle position. We then write test scenarios in equal amounts down to 10 Bar minimum (which represents a very light throttle position). This enables us to see the shift results at varying throttle positions. Our experience has shown us that there is no standard throttle position where a fault occurs. Sometimes it may be at very light throttle and other times a fault may only show at a much higher position.



II.9: I need a Valve Body testing unit built based on my tech specifications because we develop our own products. Is it possible to change the standard tech specifications option ?

We have vast experience of working on exclusive projects for our clients. In the event you require extra features adding to our specifications, we require that you list them individually. Our engineering team will then assess the feasibility, pricing and lead time of your project.



II.11: VALVE BODY TECHNICAL SUBSECTION

1) Built-in features frequently asked about: - Visual indications (line chart, temperature characteristics, pressure, date and time) of the total process with a possibility to archive the received data; - Test bench control shall be performed automatically and manually; - Quick-release connection of Valve Body to the test bench; - Oil filtering system; - Oil heating system: dual monitoring allows to observe temperature in the tank and at the valve body. 2) Is it possible for HTC-K software to create acceptance report based on the measured results ? We offer a resulting PDF file created in Test Scenario mode at the end of the each test. It contains the main conclusions regarding performance of a particular Valve Body. The greatest benefit is that this feature allows a visually explicit comparison against the benchmark data. 3) How often is the HTC-K software updated and how flexible is this process ? The software is flexible and easily accepts any new features that customers may request. We have a team of software and hardware engineers who assist in the accomplishment of these tasks on a continuous basis. We strive to improve at all times and the design features of our software allow for future improvements. 4) Is there a detailed technical datasheet which describes all possibilities of the test bench ? We have a video guide to allow users to operate our software and see its capabilities in a Demo Mode. In addition we have auxiliary PDF files that contribute to your better understanding. We can also connect online by various means to explain any peculiarities or overcome certain points that can be beyond easy comprehension.



II.10: Is it possible to test 2 (or more) solenoids in one session with HT-SOL?

When using our solenoid tester, we test the solenoids individually. So we would send transmission fluid into the solenoid, energise and de-energise the solenoid and then monitor the mechanical and electric performance of that solenoid. We generally mount multiple solenoids into the block where possible as shown in attached picture but we are only checking one at a time. Alternatively if we want to monitor the solenoids simultaneously, we can test them in the valve body whilst fitted to our Valve Body Test Machine.



 

HYDRA-TORQUE - TORQUE CONVERTER section

III.1: Do I need to buy the complete standard set of equipment ? Which items are essential for successful Torque converter rebuilding ?

Our standard set of equipment consists of: 1) WS 2.2 Dual Gun Welding Stand with MIG+TIG (dual chuck system for precise Torque Converter alignment during the welding process; automated MIG welding process; TIG mode for precise and pinpoint welding; automated Torque Converter internal clearance algorithm) 2) PB 2.1 Piston Bonder (application of halogen bulbs heating allows economic energy consumption; steel adapter plates contribute to a more affordable price; adapter plates from steel are easy to produce if needed above the standard set that we supply) 3) ATS 2.1 Leak tester (air test stand) 4) PTS 2.1 Preload tester (used for 6HP** converters by ZF; these converters are very popular and PTS 2.1 has become a must-have item for Torque Converter repair workshops) 5) ICS 2.1 End play tool (used to measure internal clearance within a welded Converter) 6) LTK 360 Tooling for lathe machine to accurately cut open Torque Converters. 7) RT 2.1 - Riveter tool to work with DP0/AL4 Converters. 8) BS 2.1 - Torque Converter Balancer stand is used to confirm the final quality to workshop customers. Top professional service centres use balancing machines as part of their process to comply with OEM requirements. 9) ACS 2.1 - Alignment check stand used to check Impeller Hub/Neck or Body runout. This tool is supplementary because its functions can be covered by the dial indicator that is fitted on the welding stand WS 2.2 10) ITK-S - Standard tool kit used during replacement of an Impeller hub.



III.2: What equipment and tools do I need in addition to the Hydra-Torque equipment ?

In addition to our range of equipment rebuilders will require: - A heavy duty lathe for cutting open the torque converter. Due to the size and weight of this item we recommend a customer to source this locally. Our LTK360 kit contains the necessary Faceplate items required. - A quality parts cleaning system. Generally rebuild shops have already made this investment in their normal transmission rebuild business. - Spare parts. The parts required for rebuilding a torque converter are minimal when compared to rebuilding a transmission unit. Most reputable Parts suppliers worldwide stock all the parts required. Our engineers can advise a customer on these requirements too.



III.3: What skills are needed for working on Torque Converter rebuilding equipment ?

Previous experience of working with industrial machinery will certainly contribute to easier and faster understanding of the rebuilding routine. The cut-open procedure for Torque Converters is potentially the most skilled operation and engineering experience is an advantage but not essential. The welding process is simple because the welding procedure is automated. Removing and replacing a worn-out friction lining is a skill that can be easily acquired. The entire process is covered during the hand-on training package conducted at our working facility in Kettering. Free training and introductory advice is given free of charge to our customers.



III.4: What are the gas mixture and welding wire selection for a Hydra-Torque welding stand?

Typically, 80% СО2 / 20% argon. but other mix ratios typical for use in Transmission workshops are also appropriate. The welding wire to be used is the 0.8mm diameter one.



III.5: What are the maximum dimensions for a Torque Converter to be put on the Welding stand WS 2.2?

Max diameter for the welded Converter = 460mm.
Max height of the welded Converter = 280mm.
Max diameter of the clamp in the lower chuck = 50mm.
Max diameter of the clamp in the upper chuck = 125mm.



 

© 2016 Cottingham Engineering

Kettering, UK

+44 (0) 1536 511123

sales@hydratest.co.uk