Bench Test Procedure for a 776B, 776C, 776D, 777B, 777C, and 777D Off-Highway Truck Transmission {3030, 3073} Caterpillar

Quarry Truck

777D (S/N: FKR1-UP)

Tractor

776B (S/N: 6JC1-UP)

776C (S/N: 2TK1-UP)

776D (S/N: 5ER1-UP; AFS1-UP)

Truck

777B (S/N: 4YC1-UP)

777C (S/N: 4XJ1-UP)

777D (S/N: AGC1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS1672
09	Standardized.
08	Added serial number FKR.
07	Updated Lube Check section. Added Table 13.
06	Updated Lube Check section, Table, and14 Table 15.
05	Updated Table 14.

© 2016 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 special instruction contains the necessary information that is required to bench test a specific transmission arrangement. Refer to Table 2 for the correct arrangements. Bench testing the transmission ensures correct assembly and operation of the component. Rotating a transmission provides the most conclusive evaluation. Testing allows the dealer to ensure that the transmission will operate properly in the machine. The specifications in this guideline are specific to bench testing the component. 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 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. To address an urgent issue, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

• Knowledge Network

Table 2

Machine Model	Transmission Arrangement
776B	3T-0278, 9W-9303
776C	8E-9035
776D	8E-9035
777B	3T-0278, 9W-9303
777C	8E-9035
777D	8E-9035

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 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 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 to develop this test procedure.

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9584	Rail As	2
	1U-9586	Swivel Head Support Gp	1
	1U-9585	Block Gp (Transmission Mounting)	1
	FT-2278	Swivel Head Support Gp	2
B	4C-9908	Drive Adapter	1
	5B-0841	Bolt (5/8-18X1.75 inch)	4
	3B-4510	Lockwasher	4
C	1U-9131	Drive Adapter (Key)(1)	1
D	1U-9359	Drive Adapter(2)	1
E	1U-5810	Plate As (Spindle Adapter)	1
	1A-8063	Bolt (3/4-10X2.5 inch)	2
	5P-8248	Hard Washer	2
	2J-3506	Full Nut	2
F	1U-9722	Load Binder As (Ratchet Type)	3
	439-3939	Link Bracket As	2
	1A-8063	Bolt (3/4-10X2.5 inch)	2
	5P-8248	Hard Washer	2
	2J-3506	Full Nut	2
G	1U-8653	Adapter (Splined)	1
H	1U-5999	Spindle Gp	1
	8B-7997	Bolt (1/2-13X2.0 inch)	4
	3B-4508	Lockwasher	4
R	3B-6552	Elbow	1
	3B-7282	Pipe Nipple	1
	6V-4142	Fitting (Test)	1
J	4C-4897	Cover (Transmission Test)	1
K	1U-8304	Fitting	1
	9U-7446	Adapter	1
	1P-4579	Half Flange	2
	8C-9024	Fitting As (Plain)	1
	6V-3965	Fitting As (Quick Disconnect)	1
	3J-1907	O-Ring Seal	1
	1A-5822	Bolt (1/2-13X2.75 inch)	4
	5P-8245	Hard Washer	4
L	1U-5794	Adapter	1
	1L-4031	Service Tee	2
	061-9593	Reducer Bushing	2
	6B-5072	Terminal Bushing	2
	8C-9024	Fitting As (Plain)	2
	6V-3966	Fitting As (Valve)	2
	0V-0375	Bolt (1/2-13X3.25 inch)	4
	5P-8245	Hard Washer	4
	3B-4508	Lockwasher	4
M	8C-9024	Fitting As (Plain)	1
	8C-9025	Quick Coupler	1
	3B-7749	Fitting	1
	120-6843	Ball Valve	1
N	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	10
	6V-4144	Coupler	10
S	8T-0863	Pressure Gauge (0 to 250 kPa (0 to 36 psi))	2
	6V-4144	Coupler	2
P	9U-7500	Transmission Analyzer Tool Gp	1
	OR
	277-2362	Transmission Analyzer Gp	1
	9U-7498	Extension Cable	1
	1U-9482	Adapter Cable As	1
	4C-5974	Cable Adapter	2

(1)	This drive adapter is used with the small drive shaft.
(2)	This drive adapter is used with the large drive shaft.

FT Drawings

Illustration 3	g03836221
FT-2278 (A) 0L-1169 Bolt (B) 2S–7593 Hard Washer (C) 1D-4720 Nut

Tools Needed (Optional Procedure)

Illustration 4	g01012642

Table 4

Required Tools
Tool	Part Number	Part Description	Qty
Q	131-5050	DataView Tool Gp(1)	1
	148-9610	Computer Cart Gp	1
	4C-6818	Pressure Sensor (0 to 500 psi)	7
	6V-4144	Coupler	7
	131-5054	Adapter Cable As (Pressure Sensor)	7
	6V-2198	Cable	7

(1)	The compatible computer system is not included.

Installation Procedure

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Illustration 5	g06034276

1. Install Tooling (A) on the rails of the test bench.
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   Illustration 6	g01002820

2. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1610 kg (3550 lb).
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   Illustration 7	g01002821

3. Install Tooling (B) to the input yoke.
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   Illustration 8	g01002822

4. Install Tooling (C) on Tooling (B).

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

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   Illustration 9	g01002823

5. Align the transmission with the input drive shaft.

6. Connect the input drive shaft to Tooling (C).
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   Illustration 10	g01002824

7. Install the drive shaft guard.
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   Illustration 11	g03802221

8. Tighten all four castle nuts and jack bolts.
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   Illustration 12	g01002825

9. Use a hoist to remove shipping cover (1). The weight of shipping cover (1) is 50 kg (110 lb).
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   Illustration 13	g01002826

10. Remove O-ring seal (2) from shipping cover (1).

    Note: O-ring seal (2) will be installed on Tooling (E).

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    Illustration 14	g01002827

11. Use a hoist to install Tooling (E) on the transmission case. The weight of Tooling (E) is 50 kg (110 lb).
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    Illustration 15	g06043672

12. Install two bolts in the bottom locations.
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    Illustration 16	g01002829

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    Illustration 17	g01002830

13. Install Tooling (F) in the top locations.
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    Illustration 18	g01002831

14. Install Tooling (F) to the input end of the transmission.
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    Illustration 19	g01002832

15. Install Tooling (F) to the output end of the transmission.
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    Illustration 20	g01002833

16. Install Tooling (G).
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    Illustration 21	g01002834

    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.

17. Use a hoist to install Tooling (H) on Tooling (E). The weight of Tooling (H) is 121 kg (267 lb).
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    Illustration 22	g01002835

18. Loosen bolt (3).
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    Illustration 23	g01002836

19. Use bolt (2) to adjust Tooling (G) inward until Tooling (H) contacts the carrier. Tooling (H) will slide on Tooling (G).
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    Illustration 24	g01002837

20. Tighten the collet on Tooling (H) to connect Tooling (H) to Tooling (G).

21. Adjust Tooling (H) to provide a 3 - 4 mm (0.12 - 0.16 inch) gap spacing between Tooling (H) and the carrier.

    Note: The measurement may be taken through the access hole in Tooling (E).

22. Tighten bolt (3).
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    Illustration 25	g01002838

23. Remove plugs (5).
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    Illustration 26	g01002840

24. Remove plug (6).
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    Illustration 27	g01002841

25. Remove bracket (7).
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    Illustration 28	g01002842

26. Remove cover (8).
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    Illustration 29	g01002843

27. Remove plug (9).
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    Illustration 30	g03331046

28. Install Tooling (R).
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    Illustration 31	g01002845

29. Install Tooling (J).
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    Illustration 32	g01002846

30. Remove cover (10).
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    Illustration 33	g01002847

31. Install Tooling (K).
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    Illustration 34	g01002848

32. Remove cover (11).
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    Illustration 35	g01002849

33. Remove tubes (12), O-ring seals (13), and O-ring seals (14).
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    Illustration 36	g01002850

34. Install tubes (12), O-ring seals (13), and O-ring seals (14) on Tooling (L).
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    Illustration 37	g01002851

35. Install Tooling (L).
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    Illustration 38	g01002852

36. Connect Tooling (M) to Tooling (L).
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    Illustration 39	g01002853
    Transmission Supply Port

37. Connect hose assembly (15) from the pressurized flow meter to Tooling (K).
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    Illustration 40	g01002854
    Oil Cooler Outlet

38. Connect hose assembly (16) from Tooling (M) to the No. 2 flow meter inlet.

    Note: The No. 2 flow meter will measure the output flow that is returning to the transmission lubrication port.

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    Illustration 41	g01002855
    Transmission Lubrication Port

39. Connect hose assembly (17) from the No. 2 flow meter outlet to Tooling (L).
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    Illustration 42	g01002856

40. Connect lube line (18) from the test bench to Tooling (H). Maintain an oil pressure of 275 kPa (40 psi).
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    Illustration 43	g01002857
    (19) Pressure Tap "A" for the No. 4 Clutch (20) Pressure Tap "B" for the No. 2 Clutch (21) Pressure Tap "C" for the No. 1 Clutch (22) Pressure Tap "E" for the No. 5 Clutch (23) Pressure Tap "F" for the No. 6 Clutch (24) Pressure Tap "G" for the No. 7 Clutch (25) Pressure Tap "H" for the No. 3 Clutch

    Note: If you are using individual pressure gauges to measure the pressures, refer to Table 3 for the correct pressure gauges.

41. Connect Tooling (N) to pressure taps (19), (20), (21), (22), (23), (24), and (25).
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    Illustration 44	g01002858
    Pressure Tap for the Priority Reducing Valve (Pilot Oil Pressure)

42. Connect Tooling (N) to Tooling (R).
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    Illustration 45	g01002859
    Transmission Control Supply Pressure

43. Connect Tooling (N) to Tooling (K).
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    Illustration 46	g01002860
    Pressure Tap for the Relief Valve for Transmission Oil Cooler

44. Connect Tooling (N) to Tooling (L).
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    Illustration 47	g03331052
    Transmission Lubrication Pressure Tap

45. Connect Tooling (S) to Tooling (L).
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    Illustration 48	g06034361
    (26) Pressure Tap for the Transfer Gear Lube

46. Connect Tooling (S) to pressure tap (26).
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    Illustration 49	g01002865
    (27) Upshift Solenoid (28) Downshift Solenoid

47. Connect Tooling (P) to solenoid (27) and solenoid (28).
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    Illustration 50	g01002867

48. Connect Tooling (P) to harness connector (29).
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    Illustration 51	g01002868

49. Connect Tooling (P) to a suitable location.
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    Illustration 52	g00877510
    Tooling (P)

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    Illustration 53	g01457869
    Tooling (P)

50. Connect Tooling (P) to a power source. Refer to Tool Operating Manual, NEHS0644 or Tool Operating Manual, NEHS0996 for the correct operating instructions.

    Note: Make sure that the transmission is secured to the test bench. Tighten all bolts to the proper torque.

Test Procedure

TA3 Navigation

1. Select “Off-Highway Trucks”.

2. Select “776B-24V”, “776C-24V”, “776D-24V”, “777B-24V”, “777C-24V”, or “777D-24V”.

Harness Test (TA3 only)

1. Make sure that the harness is properly connected.

2. Use Tooling (P) to perform the harness test.

3. Record the values in Table 7.

   Note: Do not continue testing until Harness Test passes.

Solenoid Test (TA2 only)

1. Make sure that the harness is properly connected.

2. Use Tooling (P) to perform the solenoid test.

3. Record the values in Table 7.

   Note: Do not continue testing until Solenoid Test passes.

Start Checks

Note: Refer to Testing and Adjusting, SENR3143-01, "776B Tractor and 777B Truck Power Train" for the correct adjusting procedures.

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 input flow to 110 ± 4 L/min (29 ± 1 US gpm).
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   Illustration 54	g02720621

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 800 ± 30 rpm.

   Note: The input shaft will be rotated in a counterclockwise direction for the duration of this test. The direction is determined as you face the drive motor of the test bench.

4. Shift the transmission through all gears to eliminate air from the transmission controls.

5. Confirm the correct clutch engagement with Table 5.
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   Table 5

   Clutch Engagement Check
   Gear	Cl 1	Cl 2	Cl 3	Cl 4	Cl 5	Cl 6	Cl 7
   N1	X
   N2	X
   R	X						X
   F1		X				X
   F2	X					X
   F3			X			X
   F4	X				X
   F5			X		X
   F6	X			X
   F7			X	X

6. Stop the input shaft.

Priority Reducing Valve

1. Adjust the input flow for the transmission control to 110 ± 4 L/min (29 ± 1 US gpm).

2. Adjust the input rotation to 800 ± 30 rpm in the NEUTRAL 2 position.

3. Shift the transmission to the FORWARD 1 position.

4. Check the pressure for the priority reducing valve. The correct pressure must be 1725 ± 70 kPa (250 ± 10 psi).

5. Record the value in Table 8.

Neutralizer Valve

Note: Eliminate all incoming flow before performing this test. Shutting down the test bench may be necessary.

1. Stop the input rotation in any range. Do not stop the input rotation in NEUTRAL 1 or NEUTRAL 2. Stop input to the transmission.

2. Adjust the input flow for the transmission control to 106 ± 4 L/min (28 ± 1 US gpm).

3. Adjust the input rotation to 800 ± 30 rpm.

4. The neutralizer valve must prevent a pressure increase at any clutch station.

5. Record the values in Table 9.

6. Shift the transmission to the NEUTRAL 1 position. The clutch pressure that is measured at pressure tap "C" must rise to a normal pressure.

7. Record the value in Table 10.

Transmission Cooler Inlet Relief Valve

1. Adjust the input rotation to 0 rpm.

2. Adjust the input flow for the transmission control until the outlet flow for the cooler outlet is 38 ± 4 L/min (10 ± 1 US gpm).

3. Shift the transmission to FORWARD 1.

4. Use Tooling (M) to block the flow at the torque converter outlet.

5. The inlet pressure for the transmission oil cooler must be 930 ± 138 kPa (135 ± 20 psi).

6. Record the value in Table 10.

Lube Circuit Check

1. Shift the transmission to FORWARD 2.

2. Adjust the input rotation to 1925 ± 30 rpm.

3. Adjust the input flow for the transmission control until the lube output flow is 150 ± 4 L/min (40 ± 1 US gpm). Maintain this flow during this check.

4. The lubrication pressure must be 69 ± 14 kPa (10 ± 2 psi). This pressure is measured at the transfer gear lube.

5. Record the value in Table 12.

6. Stop the input rotation.

7. Stop the input flow.

Lube Check

1. Adjust the input flow for the transmission control to 110 ± 4 L/min (29 ± 1 US gpm).

2. Adjust the input rotation to 800 ± 30 rpm.

3. Shift the transmission to the FORWARD 1 position.

4. Record the lubrication pressure in Table 14.

5. Record the lube flow in Table 14.

6. Confirm values with Table 13.

7. Shift the transmission to the NEUTRAL position.

8. Repeat Steps 4 through 6.

9. Shift the transmission to the REVERSE position.

10. Repeat Steps 4 through 6.

11. The lubrication pressure must be minimum 21 kPa (3 psi).

12. With the transmission in NEUTRAL, adjust the input flow for the transmission control to 170 ± 4 L/min (45 ± 1 US gpm).

13. Adjust the input rotation to 800 ± 30 rpm.

14. Shift the transmission to the FORWARD 1 position.

15. Adjust the input rotation to 1925 ± 30 rpm.

16. Record the lubrication pressure in Table 15.

17. Record the lube flow in Table 15.

18. Confirm values with Table 13.

19. Adjust the input rotation to 800 ± 30 rpm.

20. Shift the transmission through positions FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, FORWARD 7, and REVERSE. Repeat Steps 13 through 18 for each gear range.

    Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.

21. The lubrication pressure must be minimum 55 kPa (8 psi).

Primary Pressure Check

1. Remove Tooling (J).
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   Illustration 55	g01196228

2. Remove the load piston plugs (30) from selector valve "A", "B", "C", "E", "F", "G", and "H".

3. Install Tooling (J).

4. Adjust the input flow for the transmission control to 110 ± 4 L/min (29 ± 1 US gpm).

5. The minimum supply pressure is 2690 kPa (390 psi) in all speed ranges.

6. Adjust the input rotation to 800 ± 30 rpm.

7. Shift the transmission through each gear range.

   Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.

8. Record the primary clutch pressure for each gear range in Table 17.

9. Verify that the primary clutch pressures match the values in Table 16.

Pressure Check (Low Idle)

1. Remove Tooling (J).

2. Install load piston plugs (30). Refer to Special Instruction, "Pressure Check (Primary)".

3. Install Tooling (J).

4. Adjust the input flow for the transmission control to 110 ± 4 L/min (29 ± 1 US gpm).

5. The minimum supply pressure is 2690 kPa (390 psi) in all speed ranges.

6. Adjust the input rotation to 800 ± 30 rpm in the NEUTRAL 1 position.

7. Shift the transmission through ranges NEUTRAL 1, NEUTRAL 2, REVERSE, and FORWARD 1.

   Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.

8. Record the clutch pressure for each gear range in Table 19.

9. Verify that the clutch pressures match the values in Table 18.

Pressure Check (High Idle)

1. Adjust the input flow for the transmission control to 170 ± 4 L/min (45 ± 1 US gpm).

2. The maximum supply pressure is 3100 kPa (450 psi) in all speed ranges.

3. Adjust the input rotation to 800 ± 30 rpm with the transmission in the NEUTRAL 1 position.

4. Adjust the input rotation to 1925 ± 30 rpm.

5. Record the clutch pressure in Table 21.

6. Adjust the input rotation to 800 ± 30 rpm.

7. Shift the transmission through positions NEUTRAL 2, REVERSE, FORWARD 1, FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, and FORWARD 7. Repeat Steps 4 through 6 for each gear range.

   Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.

8. Adjust the input rotation to 800 ± 30 rpm.

9. Verify that the clutch pressures match the values in Table 20.

Transmission Bench Test Data Sheet

Table 6

CATERPILLAR	Transmission Bench Test Data Sheet	Test Date:_______
		Mode:_______
Work Order:_______		Serial No.:_______

Solenoid Test

Table 7

Solenoid Test	Solenoid 1	Solenoid 2
	_______ ohms	_______ ohms

Priority Reducing Valve

Table 8

Priority Reducing Valve

Input Speed (800 ± 30 rpm) Input Flow 110 ± 4 L/min (29 ± 1 US gpm)

_______kPa _______(psi)

Neutralizer Valve

Table 9

Neutralizer Valve (Step 1)			Input Speed (800 ± 30 rpm) Input Flow 106 ± 4 L/min (28 ± 1 US gpm)
A	B	C	E	F	G	H
_______kPa _______(psi)	_______kPa _______(psi)	_______kPa _______(psi)	_______kPa _______(psi)	_______kPa _______(psi)	_______kPa _______(psi)	_______kPa _______(psi)

Table 10

Neutralizer Valve (Step 2)		Gear Range NEUTRAL 1
Station	C	_______kPa _______(psi)	The clutch pressure must rise to normal pressure.		Yes	No

Transmission Cooler Inlet Relief Valve

Table 11

Transmission Cooler Inlet Relief Valve

Input Speed (0 rpm) Input Flow 38 ± 4 L/min (10 ± 1 US gpm)

_______kPa _______(psi)

Lube Circuit Check

Table 12

Lube Circuit Check		Gear Range FORWARD 2 Output Flow 150 ± 4 L/min (40 ± 1 US gpm)
Lubrication Pressure	_______kPa _______(psi)

Lube Check (Low Idle)

Table 13

Minimum Lube Flow
Low Idle Minimum Lube Pressure 21 kPa (3 psi)
N	98 L/min (26 US gpm)
F1	95 L/min (25 US gpm)
R	98 L/min (26 US gpm)
High Idle Minimum Lube Pressure 55 kPa (8 psi)
R	159 L/min (42 US gpm)
F1	159 L/min (42 US gpm)
F2	159 L/min (42 US gpm)
F3	155 L/min (41 US gpm)
F4	159 L/min (42 US gpm)
F5	155 L/min (41 US gpm)
F6	151 L/min (40 US gpm)
F7	148 L/min (39 US gpm)

Table 14

Lube Check (Low Idle)	Input Speed (800 ± 30 rpm) Input Flow 110 ± 4 L/min (29 ± 1 US gpm) Lube Pressure minimum 21 kPa (3 psi)
Gear	Lubrication Pressure	Lube Flow
N	_______kPa _______(psi)	_______L/min _______(US gpm)
F1	_______kPa _______(psi)	_______L/min _______(US gpm)
R	_______kPa _______(psi)	_______L/min _______(US gpm)

Lube Check (High Idle)

Table 15

Lube Check (High Idle)	Input Speed (1925 ± 30 rpm) Input Flow 170 ± 4 L/min (45 ± 1 US gpm) Lube Pressure minimum 55 kPa (8 psi)
Gear	Lubrication Pressure	Lube Flow
R	_______kPa _______(psi)	_______L/min _______(US gpm)
F1	_______kPa _______(psi)	_______L/min _______(US gpm)
F2	_______kPa _______(psi)	_______L/min _______(US gpm)
F3	_______kPa _______(psi)	_______L/min _______(US gpm)
F4	_______kPa _______(psi)	_______L/min _______(US gpm)
F5	_______kPa _______(psi)	_______L/min _______(US gpm)
F6	_______kPa _______(psi)	_______L/min _______(US gpm)
F7	_______kPa _______(psi)	_______L/min _______(US gpm)

Primary Pressure Check

Table 16

Primary Clutch Pressures
Station		"A"	"B"	"C"	"E"	"F"	"G"	"H"
Gear	Engaged Clutches	Cl 4(1)	Cl 2(1)	Cl 1(1)	Cl 5(1)	Cl 6(1)	Cl 7(1)	Cl 3(1)
N1	1			345 kPa (50 psi)
N2	1			345 kPa (50 psi)
R	1 and 7			345 kPa (50 psi)			415 kPa (60 psi)
F1	2 and 6		275 kPa (40 psi)			415 kPa (60 psi)
F2	1 and 6			345 kPa (50 psi)		415 kPa (60 psi)
F3	3 and 6					415 kPa (60 psi)		550 kPa (80 psi)
F4	1 and 5			345 kPa (50 psi)	345 kPa (50 psi)
F5	3 and 5				345 kPa (50 psi)			550 kPa (80 psi)
F6	1 and 4	515 kPa (75 psi)		345 kPa (50 psi)
F7	3 and 4	515 kPa (75 psi)						550 kPa (80 psi)

(1)	The tolerance is + 50 − 35 kPa (+ 7 − 5 psi).

Table 17

Primary Pressure Check			The Load Piston Plugs are removed. Input Speed (800 ± 30 rpm)
Station	Clutch	Specification	Original Pressure	Amount of Adjustment	Last Pressure
A	4	515 kPa (75 psi) (1)
B	2	275 kPa (40 psi)(1)
C	1	345 kPa (50 psi)(1)
E	5	345 kPa (50 psi)(1)
F	6	415 kPa (60 psi)(1)
G	7	415 kPa (60 psi)(1)
H	3	550 kPa (80 psi)(1)

(1)	The tolerance is + 50 − 35 kPa (+ 7 − 5 psi).

Pressure Check (Low Idle)

Table 18

Pressure Check (Low Idle)
Station		"A"	"B"	"C"	"E"	"F"	"G"	"H"
Gear	Engaged Clutches	Cl 4(1)	Cl 2(1)	Cl 1(1)	Cl 5(1)	Cl 6(1)	Cl 7(1)	Cl 3(1)
N1	1			2790 kPa (405 psi)
N2	1			2790 kPa (405 psi)
R	1 and 7			2790 kPa (405 psi)			2760 kPa (400 psi)
F1	2 and 6		2375 kPa (345 psi)			2590 kPa (375 psi)

(1)	The tolerance is + 240 − 100 kPa (+ 35 − 15 psi).

Table 19

Pressure Check (Low Idle)				Load Pistons are installed. Input Speed (800 ± 30 rpm)
Gear	Engaged Clutches	A Cl 4	B Cl 2	C Cl 1	E Cl 5	F Cl 6	G Cl 7	H Cl 3
N1	1
N2	1
R	1 and 7
F1	2 and 6

Pressure Check (High Idle)

Table 20

Pressure Check (High Idle)
Station		"A"	"B"	"C"	"E"	"F"	"G"	"H"
Gear	Engaged Clutches	Cl 4(1)	Cl 2(1)	Cl 1(1)	Cl 5(1)	Cl 6(1)	Cl 7(1)	Cl 3(1)
N1	1			2860 kPa (415 psi)
N2	1			2860 kPa (415 psi)
R	1 and 7			2860 kPa (415 psi)			2790 kPa (405 psi)
F1	2 and 6		2375 kPa (345 psi)			2590 kPa (375 psi)
F2	1 and 6			2860 kPa (415 psi)		2590 kPa (375 psi)
F3	3 and 6					2590 kPa (375 psi)		1860 kPa (270 psi)
F4	1 and 5			2860 kPa (415 psi)	2435 kPa (353 psi)
F5	3 and 5				2435 kPa (353 psi)			1860 kPa (270 psi)
F6	1 and 4	1410 kPa (205 psi)		2860 kPa (415 psi)
F7	3 and 4	1410 kPa (205 psi)						1860 kPa (270 psi)

(1)	The tolerance is + 240 − 100 kPa (+ 35 − 15 psi).

Table 21

Pressure Check (High Idle)				Load Pistons are installed. Input Speed (1925 ± 30 rpm)
Gear	Engaged Clutches	A Cl 4	B Cl 2	C Cl 1	E Cl 5	F Cl 6	G Cl 7	H Cl 3
N1	1
N2	1
R	1 and 7
F1	2 and 6
F2	1 and 6
F3	3 and 6
F4	1 and 5
F5	3 and 5
F6	1 and 4
F7	3 and 4

Contamination Control

Table 22

ISO Particle Count

Sample the test bench oil supply.

________/________Particle Count

Table 23

______________________________________ Technician

______________________________________ Supervisor

Shift Traces (Optional Procedure)

Introduction

Shift traces have become an important tool for validating the proper operation and assembly of the component. The shift cycles are recorded and reviewed to analyze the specific segments of the shift cycle. The segments are decay times, fill times, and modulation times. Shift traces can reveal faulty parts or omitted parts. Shift traces can alert the technician to potential problems.

Correct interpretation of terminology is essential for understanding shift traces. Refer to Illustration 57 and Illustration 58 to interpret your shift traces correctly.

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 used to compare values on portions of this transmission test. 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.

These averages should be entered on the shift trace worksheets. A typical example is included on each worksheet.

Note: Refer to Table 4 for the required tooling.

Show/hide table

Illustration 56	g01003526

1. Install Tooling (Q) on pressure taps, "A", "B", "C", "E", "F", "G", and "H".

Illustration 57	g00899108

Illustration 58	g00899331

Shift Trace NEUTRAL 1 to FORWARD 1

Table 24

Data View Graph Definition
Selected Channels	1, 2, 6
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	1925 rpm

Table 25

Channel Assignments
Data Channel		1	2	6
Clutch Station		C	B	F
Sample Rate		100 per sec

Illustration 59	g01003630

Table 26

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	1	.04 sec ± 15%	_____________ sec	_____________ sec
Fill Time	2	.17 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	2	.47 sec ± 15%	_____________ sec	_____________ sec
Fill Time	6	.40 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	6	.57 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 1 to FORWARD 2

Table 27

Data View Graph Definition
Selected Channels	1, 2, 6
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	1925 rpm

Table 28

Channel Assignments
Data Channel		1	2	6
Clutch Station		C	B	F
Sample Rate		100 per sec

Illustration 60	g01003631

Table 29

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	2	.29 sec ± 15%	_____________ sec	_____________ sec
Fill Time	1	.22 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	1	.31 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 2 to FORWARD 3

Table 30

Data View Graph Definition
Selected Channels	1, 3, 6
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	1925 rpm

Table 31

Channel Assignments
Data Channel		1	3	6
Clutch Station		C	H	F
Sample Rate		100 per sec

Illustration 61	g01003632

Table 32

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	1	.04 sec ± 15%	_____________ sec	_____________ sec
Fill Time	3	.29 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	3	.34 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 3 to FORWARD 4

Table 33

Data View Graph Definition
Selected Channels	1, 3, 5, 6
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	1925 rpm

Table 34

Channel Assignments
Data Channel		1	3	5	6
Clutch Station		C	H	E	F
Sample Rate		100 per sec

Illustration 62	g01003633

Table 35

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	3	.11 sec ± 15%	_____________ sec	_____________ sec
Decay Time	6	.16 sec ± 15%	_____________ sec	_____________ sec
Fill Time	1	.22 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	1	.31 sec ± 15%	_____________ sec	_____________ sec
Fill Time	5	.13 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	5	.61 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 4 to FORWARD 5

Table 36

Data View Graph Definition
Selected Channels	1, 3, 5
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	1925 rpm

Table 37

Channel Assignments
Data Channel		1	3	5
Clutch Station		C	H	E
Sample Rate		100 per sec

Illustration 63	g01003634

Table 38

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	1	.04 sec ± 15%	_____________ sec	_____________ sec
Fill Time	3	.28 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	3	.34 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 5 to FORWARD 6

Table 39

Data View Graph Definition
Selected Channels	1, 3, 4, 5
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	1925 rpm

Table 40

Channel Assignments
Data Channel		1	3	4	5
Clutch Station		C	H	A	E
Sample Rate		100 per sec

Illustration 64	g01003635

Table 41

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	3	.11 sec ± 15%	_____________ sec	_____________ sec
Decay Time	5	.15 sec ± 15%	_____________ sec	_____________ sec
Fill Time	1	.22 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	1	.31 sec ± 15%	_____________ sec	_____________ sec
Fill Time	4	.21 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	4	.30 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 6 to FORWARD 7

Table 42

Data View Graph Definition
Selected Channels	1, 3, 4
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	1925 rpm

Table 43

Channel Assignments
Data Channel		1	3	4
Clutch Station		C	H	A
Sample Rate		100 per sec

Illustration 65	g01003636

Table 44

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	1	.04 sec ± 15%	_____________ sec	_____________ sec
Fill Time	3	.28 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	3	.34 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 7 to FORWARD 6

Table 45

Data View Graph Definition
Selected Channels	1, 3, 4
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	1265 rpm

Table 46

Channel Assignments
Data Channel		1	3	4
Clutch Station		C	H	A
Sample Rate		100 per sec

Illustration 66	g01003637

Table 47

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	3	.11 sec ± 15%	_____________ sec	_____________ sec
Fill Time	1	.22 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	1	.31 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 6 to FORWARD 5

Table 48

Data View Graph Definition
Selected Channels	1, 3, 4, 5
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	1265 rpm

Table 49

Channel Assignments
Data Channel		1	3	4	5
Clutch Station		C	H	A	E
Sample Rate		100 per sec

Illustration 67	g01003638

Table 50

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	1	.04 sec ± 15%	_____________ sec	_____________ sec
Decay Time	4	.11 sec ± 15%	_____________ sec	_____________ sec
Fill Time	3	.26 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	3	.34 sec ± 15%	_____________ sec	_____________ sec
Fill Time	5	.13 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	5	.61 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 5 to FORWARD 4

Table 51

Data View Graph Definition
Selected Channels	1, 3, 5
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	1265 rpm

Table 52

Channel Assignments
Data Channel		1	3	5
Clutch Station		C	H	E
Sample Rate		100 per sec

Illustration 68	g01003639

Table 53

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	3	.11 sec ± 15%	_____________ sec	_____________ sec
Fill Time	1	.22 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	1	.31 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 4 to FORWARD 3

Table 54

Data View Graph Definition
Selected Channels	1, 3, 5, 6
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	1265 rpm

Table 55

Channel Assignments
Data Channel		1	3	5	6
Clutch Station		C	H	E	F
Sample Rate		100 per sec

Illustration 69	g01003640

Table 56

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	1	.04 sec ± 15%	_____________ sec	_____________ sec
Decay Time	5	.15 sec ± 15%	_____________ sec	_____________ sec
Fill Time	3	.25 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	3	.34 sec ± 15%	_____________ sec	_____________ sec
Fill Time	6	.42 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	6	.57 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 3 to FORWARD 2

Table 57

Data View Graph Definition
Selected Channels	1, 3, 6
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	1265 rpm

Table 58

Channel Assignments
Data Channel		1	3	6
Clutch Station		C	H	F
Sample Rate		100 per sec

Illustration 70	g01003641

Table 59

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	3	.11 sec ± 15%	_____________ sec	_____________ sec
Fill Time	1	.22 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	1	.31 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 2 to FORWARD 1

Table 60

Data View Graph Definition
Selected Channels	1, 2, 6
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	1265 rpm

Table 61

Channel Assignments
Data Channel		1	2	6
Clutch Station		C	B	F
Sample Rate		100 per sec

Illustration 71	g01003642

Table 62

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	1	.04 sec ± 15%	_____________ sec	_____________ sec
Fill Time	2	.16 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	2	.47 sec ± 15%	_____________ sec	_____________ sec

Shift Trace FORWARD 1 to NEUTRAL 1

Table 63

Data View Graph Definition
Selected Channels	1, 2, 6
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	1265 rpm

Table 64

Channel Assignments
Data Channel		1	2	6
Clutch Station		C	B	F
Sample Rate		100 per sec

Illustration 72	g01003643

Table 65

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	2	.29 sec ± 15%	_____________ sec	_____________ sec
Decay Time	6	.16 sec ± 15%	_____________ sec	_____________ sec
Fill Time	1	.22 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	1	.31 sec ± 15%	_____________ sec	_____________ sec