Bench Test Procedure for a 773D, 773E, 775D, and 775E Off-Highway Truck Transmission {3030, 3073} Caterpillar

Off Highway Truck

773E (S/N: KEG1-UP; ASK1-UP; DJS1-UP)

773E Series 2 (S/N: PRB1-UP)

Quarry Truck

773D (S/N: NBJ1-UP)

775D (S/N: 8AS1-UP)

Truck

773D (S/N: 7ER1-UP; 7CS1-UP)

773E (S/N: BDA1-UP)

775D (S/N: 6KR1-UP)

775E (S/N: BEC1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS1749
06	Standardized.
05	Added KEG serial number prefix
04	Added new introduction and Canceled Part Numbers section.

© 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
773D	145-7407
773E	145-7407
775D	145-7407
775E	145-7407

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 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.

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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 extra 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	1
	1U-9585	Block Gp (Transmission Mounting)	13
B	4C-4627	Adapter Plate	1
	0S-1603	Bolt (1/2-20X1.50 inch)	4
C	136-3647	Adapter Plate	1
	0S-1594	Bolt (3/8-16X1.00 inch)	4
D	1U-9131	Drive Adapter (Key)(1)	1
E	1U-9722	Load Binder As (Ratchet Type)	2
	439-3940	Link Bracket As	2
F	4C-9440	Plate as (Spindle Adapter)	1
	5H-4893	Bolt (1/2-13X1.00 inch)	4
G	4C-9441	Adapter (Splined)	1
H	1U-5999	Spindle Gp	1
	8B-7997	Bolt (1/2-13X2.0 inch)	4
Q	3B-6552	Elbow	1
	3B-7282	Pipe Nipple	1
	6V-4142	Fitting (Test)	1
J	4C-4898	Cover (Transmission Test)	1
K	1U-8304	Fitting	3
	9U-7446	Adapter	3
	1P-4579	Half Flange	6
	8C-9024	Fitting As (Plain)	3
	6V-3965	Fitting As (Quick Disconnect)	3
	3J-1907	O-Ring Seal	3
	7X-0325	Bolt (1/2-13X2.5 inch)	12
	8T-4223	Hard Washer	12
L	8C-9024	Fitting As (Plain)	1
	8C-9025	Quick Coupler	1
	3B-7749	Fitting	1
	120-6843	Ball Valve	1
M	8J-7844	Adapter Fitting	1
	6V-3966	Fitting As (Valve)	1
	3K-0360	O-Ring Seal	1
N	4C-5974	Cable Adapters	2
	1U-9482	Adapter Cable As	1
	9U-7500	Transmission Analyzer Tool Gp	1
	OR
	277-2362	Transmission Analyzer III Gp	1
R	8T-0855	Pressure Gauge (0 kPa to 4,000 kPa (0 psi to 580 psi))	10
	6V-3989	Fitting (Test)	10
	177-7861	Hose As	10
	6V-4143	Coupler	20
P	8T-0863	Pressure Gauge (0 kPa to 250 kPa (0 psi to 36 psi))	2
	6V-3989	Fitting (Test)	2
	177-7861	Hose As	2
	6V-4143	Coupler	4

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

Installation Procedure

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Illustration 3	g03874111

1. Install Tooling (A) to the test bench.
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   Illustration 4	g01084466

2. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1906 kg (4203 lb).
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   Illustration 5	g01084470

3. Install Tooling (B) to the input yoke.
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   Illustration 6	g01084471

4. Install Tooling (C) on Tooling (B).
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   Illustration 7	g01084473

5. Connect Tooling (D) to Tooling (C).

   Note: Tooling (D) will adapt to the small drive shaft.

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   Illustration 8	g01084475

6. Align the transmission with the input drive shaft.

7. Connect the input drive shaft to Tooling (D).
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   Illustration 9	g01084476

8. Install the drive shaft guard.
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   Illustration 10	g03802221

9. Tighten all four castle nuts and jack bolts.
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   Illustration 11	g01084480

10. Install Tooling (E) to the transmission.
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    Illustration 12	g01084482

11. Install Tooling (F) to the back of the transmission case.
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    Illustration 13	g01084488

12. Install Tooling (G) to the output shaft of the transmission.
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    Illustration 14	g01084495

13. Use a hoist to install Tooling (H) on Tooling (G).

    Note: The weight of Tooling (H) is 50 kg (110 lb).

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    Illustration 15	g01084490

    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.

14. Adjust Tooling (H) to provide a 3.0 - 4.0 mm (0.12 - 0.16 inch) gap spacing between Tooling (H) and Tooling (G).
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    Illustration 16	g01084492

15. Remove bracket (1).
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    Illustration 17	g01084500

16. Remove cover (2).
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    Illustration 18	g01084503

17. Remove plug (3).
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    Illustration 19	g03874113

18. Install Tooling (Q).
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    Illustration 20	g01084518

19. Install Tooling (J).
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    Illustration 21	g01092307

20. Install Tooling (K).
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    Illustration 22	g01092304

21. Install Tooling (L) to Tooling (K).
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    Illustration 23	g01084531

22. Install Tooling (K).
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    Illustration 24	g01084532

23. Remove filter cover (4).
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    Illustration 25	g01084533

24. Remove the filter (5) from the filter assembly.
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    Illustration 26	g01084534

25. Install Tooling (M).
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    Illustration 27	g01092322

26. Connect hose assembly (6) from Tooling (L) to the No. 2 flow meter inlet.
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    Illustration 28	g01092331

27. Connect hose assembly (7) from the outlet of the No. 2 flow meter to Tooling (K).
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    Illustration 29	g01084537

28. Connect hose assembly (8) from pump supply to Tooling (K).
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    Illustration 30	g01084538

29. Connect lube line (9) from the test bench to Tooling (H). Maintain an oil pressure of 275 kPa (40 psi).
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    Illustration 31	g01084540
    (10) Pressure tap "A" for the No. 2 clutch (11) Pressure tap "B" for the No. 1 clutch (12) Pressure tap "C" for the No. 7 clutch (13) Pressure tap "E" for the No. 5 clutch (14) Pressure tap "F" for the No. 4 clutch (15) Pressure tap "G" for the No. 6 clutch (16) Pressure tap "H" for the No. 3 clutch

30. Connect pressure gauges to pressure taps (10), (11), (12), (13), (14), (15), and (16).

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

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    Illustration 32	g01084958
    Pilot Pressure

31. Connect Pressure gauge (18) to Tooling (Q).
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    Illustration 33	g01084542
    Pump Pressure

32. Connect Pressure gauge (17) to Tooling (M).
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    Illustration 34	g03874592
    Lubrication Pressure

33. Connect a pressure gauge to Pressure tap (19).
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    Illustration 35	g03874599
    (20) Upshift Solenoid (21) Downshift Solenoid

34. Connect Tooling (N) to the transmission.
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    Illustration 36	g01084551

35. Connect Tooling (N) to a suitable location.
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    Illustration 37	g00877510
    Tooling (N)

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    Illustration 38	g01457869
    Tooling (N)

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

Test Procedure

TA3 Navigation

1. Select “Off-Highway Trucks”.

2. Select “773D-24V”, “773E-24V”, “775D-24V”, or “775E-24V”.

Harness Test (TA3 only)

1. Make sure that the harness is properly connected.

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

3. Record the values in Table 6.

   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 (N) to perform the solenoid test.

3. Record the values in Table 6.

   Note: Do not continue testing until Solenoid Test passes.

Start Checks

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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.

Note: Refer to Testing and Adjusting, SENR1573, "773D Off-Highway Truck and 775D Quarry Truck Power Train", or Testing and Adjusting, RENR6509, "773E Off-Highway Truck and 775E Off-Highway Truck Power Train" for the correct adjusting procedures.

1. The preferred oil is SAE 10 oil viscosity grade. Warm SAE 10 oil viscosity grade 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 57 ± 4 L (15 ± 1 US gal).
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   Illustration 39	g02720621

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 600 ± 30 rpm.

4. Shift the transmission through all directions and through all speed ranges to eliminate air from the transmission controls.

5. Confirm the correct clutch engagement with Table 4.
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   Table 4

   Clutch Engagement Check
   Gear	Cl 1	Cl 2	Cl 3	Cl 4	Cl 5	Cl 6	Cl 7
   N				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. Check for lockup or excessive drag in all ranges.

7. Adjust the input rotation to 0 rpm.

8. Use the following procedure to test the transmission.

Priority Reducing Valve

1. Adjust the input flow to 57 ± 4 L (15 ± 1 US gal).

2. Adjust the input rotation to 650 ± 30 rpm in the NEUTRAL 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 7.

Neutralizer Valve

Note: Eliminate all incoming flow before performing this test. It may be necessary for you to shut down the test bench.

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

2. Adjust the input flow to 57 ± 4 L/min (15 ± 1 US gpm).

3. Adjust the input rotation to 650 ± 30 rpm.

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

5. Record the values in Table 8.

6. Shift the transmission to the NEUTRAL position. The clutch pressure that is measured at pressure tap "F" (14) must rise to a normal pressure.

7. Record the value in Table 9.

Relief Valve Check (Cooler Inlet)

1. With the transmission in the NEUTRAL position, adjust the input rotation to 650 ± 30 rpm.

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

3. Adjust the input flow to produce an outlet flow of 38 ± 4 L/min (10 ± 1 US gpm).

4. Shift the transmission to FORWARD 1.

5. Use Tooling (L) to block momentarily the flow at the cooler outlet.

6. The "P3" cooler outlet pressure must be 930 ± 138 kPa (135 ± 20 psi).

7. Open Tooling (L).

8. Record the value in Table 10.

9. Shift the transmission to the NEUTRAL position.

Lube Circuit Check

1. Shift the transmission to FORWARD 2.

2. Adjust the input rotation to 2150 ± 30 rpm.

3. Adjust the input flow until the lube flow is 132 ± 4 L/min (35 ± 1 US gpm). Maintain this flow during this check.

4. The lubrication pressure must be within 7 kPa (1 psi) of the average for this arrangement.

5. The expected lubrication pressure should be 103 ± 8 kPa (15 ± 1 psi).

6. Record the value in Table 11.

7. Stop the input rotation.

8. Stop the input flow.

Primary Clutch Pressure Checks

1. Remove Tooling (J).
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   Illustration 40	g01085211

2. Remove the load piston plugs (21) from selector valve "A", "B", "C", "E", "F", "G"and "H".

3. Install Tooling (J).

4. Adjust the input flow to 57 ± 4 L/min (15 ± 1 US gpm).

5. Adjust the input rotation to 650 ± 30 rpm.

6. Shift the transmission through each gear range.

   Note: DO NOT shift the transmission into REVERSE with the input rpm higher than 650 rpm.

7. Record the primary clutch pressure for each gear range in Table 13.

8. Verify that the primary clutch pressures match the values in Table 12.

9. Shift the transmission to the NEUTRAL position.

High Idle Pressure Check

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

2. Adjust the input rotation to 2150 ± 30 rpm with the transmission in the NEUTRAL position.

3. Shift the transmission through each gear range.

   Note: DO NOT shift the transmission into REVERSE with the input rpm higher than 650 rpm.

4. Record the clutch pressures in Table 15.

5. Verify that the clutch pressures match the values in Table 14.

6. Shift the transmission to the NEUTRAL position.

7. Stop the input rotation.

Contamination Control

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

2. Record the results in Table 16.

3. Remove the transmission from the test bench if the test bench oil supply is within specifications.

Transmission Bench Test Data Sheet

Table 5

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

Solenoid Test

Table 6

Solenoid Test	Solenoid 1	Solenoid 2
	_______ Ω	_______ Ω

Priority Reducing Valve

Table 7

Priority Reducing Valve

Input Speed (650 ± 30 rpm) in NEUTRAL Input Flow 57 ± 4 L/min (15 ± 1 US gpm)

_______kPa _______(psi)

Neutralizer Valve

Table 8

Neutralizer Valve (Step 1)			Input Speed (650 ± 30 rpm) Input Flow 57 ± 4 L/min (15 ± 1 US gpm)
A	B	C	D	E	F	G	H
______kPa ______(psi)	______kPa ______(psi)	______kPa _______psi)	______kPa ______(psi)	______kPa ______(psi)	______kPa ______(psi)	______kPa ______(psi)	_______Pa ______(psi)

Table 9

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

Relief Valve Check (Cooler Inlet)

Table 10

Relief Valve Check (Cooler Inlet)

Input Speed (650 ± 30 rpm)

_______kPa _______(psi)

Lube Circuit Check

Table 11

Lube Circuit Check		Gear Range FORWARD 2 Input Speed (2150 ± 30 rpm) Lube Flow 132 ± 4 L/min (35 ± 1 US gpm)
Test Data		Average	Actual
Lube Pressure		_______kPa _______(psi)	_______kPa _______(psi)

Primary Pressure Checks

Table 12

Initial Pressure Check
Station(1)(2)		"A"	"B"	"C"	"E"	"F"	"G"	"H"
Clutch		No. 2	No. 1	No. 7	No. 5	No. 4	No. 6	No. 3
Speed Position	Engaged Clutches	Pressure (3)	Pressure (3)	Pressure (3)	Pressure (3)	Pressure (3)	Pressure (3)	Pressure (3)
NEUTRAL	4	0	0	0	0	275 kPa (40 psi)	0	0
REVERSE	1 and 7	0	315 kPa (45 psi)	315 kPa (45 psi)	0	0	0	0
FIRST	1 and 6	0	315 kPa (45 psi)	0	0	0	315 kPa (45 psi)	0
SECOND	3 and 6	0	0	0	0	0	315 kPa (45 psi)	275 kPa (40 psi)
THIRD	2 and 6	415 kPa (60 psi)	0	0	0	0	315 kPa (45 psi)	0
FOURTH	3 and 5	0	0	0	310 kPa (45 psi)	0	0	275 kPa (40 psi)
FIFTH	2 and 5	415 kPa (60 psi)	0	0	315 kPa (45 psi)	0	0	0
SIXTH	3 and 4	0	0	0	0	275 kPa (40 psi)	0	275 kPa (40 psi)
SEVENTH	2 and 4	415 kPa (60 psi)	0	0	0	275 kPa (40 psi)	0	0

(1)	Station "D" is not used.
(2)	Refer to the Testing and Adjusting, "Transmission Hydraulic Control (Pressure Pack) - Test and Adjust" for the proper procedure to adjust the stations.
(3)	The tolerance is + 50 − 35 kPa (+ 7 − 5 psi).

Table 13

Primary Pressure Checks			The Load Pistons are Removed. Input Speed (650 ± 30 rpm) Input Flow 57 ± 4 L/min (15 ± 1 US gpm)
Station	Clutch	Specification(1)	Original Pressure	Amount of Adjustment	Last Pressure
A	2	415 kPa (60 psi)
B	1	315 kPa (45 psi)
C	7	315 kPa (45 psi)
E	5	310 kPa (45 psi)
F	4	275 kPa (40 psi)
G	6	315 kPa (45 psi)
H	3	275 kPa (40 psi)

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

High Idle Pressure Check

Table 14

Clutch Pressure At High Idle rpm
Station(1)(2)		"A"	"B"	"C"	"E"	"F"	"G"	"H"
Clutch		No. 2	No. 1	No. 7	No. 5	No. 4	No. 6	No. 3
Speed Position	Engaged Clutches	Pressure (3)	Pressure (3)	Pressure (3)	Pressure (3)	Pressure (3)	Pressure (3)	Pressure (3)
NEUTRAL	4	0	0	0	0	2110 kPa (305 psi)	0	0
REVERSE	1 and 7	0	2860 kPa (415 psi)	2860 kPa (415 psi)	0	0	0	0
FIRST	1 and 6	0	2860 kPa (415 psi)	0	0	0	2860 kPa (415 psi)	0
SECOND	3 and 6	0	0	0	0	0	2860 kPa (415 psi)	2275 kPa (330 psi)
THIRD	2 and 6	2140 kPa (310 psi)	0	0	0	0	2860 kPa (415 psi)	0
FOURTH	3 and 5	0	0	0	2140 kPa (310 psi)	0	0	2275 kPa (330 psi)
FIFTH	2 and 5	2140 kPa (310 psi)	0	0	2140 kPa (310 psi)	0	0	0
SIXTH	3 and 4	0	0	0	0	2110 kPa (305 psi)	0	2275 kPa (330 psi)
SEVENTH	2 and 4	2140 kPa (310 psi)	0	0	0	2110 kPa (305 psi)	0	0

(1)	Station "D" is not used.
(2)	Refer to the Power Train Testing and Adjusting, "Transmission Hydraulic Control (Pressure Pack) - Test and Adjust" for the proper procedure to adjust the Stations.
(3)	The tolerance is + 240 − 100 kPa (+ 35 − 15 psi).

Table 15

High Idle Pressure Check		Input speed (2300 ± 30 rpm) Input flow 170 ± 4 L/min (45 ± 1 US gpm)
Station		"A"	"B"	"C"	"E"	"F"	"G"	"H"
Clutch		No. 2	No. 1	No. 7	No. 5	No. 4	No. 6	No. 3
Speed Position	Engaged Clutches	Pressure	Pressure	Pressure	Pressure	Pressure	Pressure	Pressure
NEUTRAL	4
REVERSE	1 and 7
FIRST	1 and 6
SECOND	3 and 6
THIRD	2 and 6
FOURTH	3 and 5
FIFTH	2 and 5
SIXTH	3 and 4
SEVENTH	2 and 4

Contamination Control

Table 16

Contamination Control

Sample the test bench oil supply.

________/________Particle Count

Table 17

______________________________________ Technician

______________________________________ Supervisor