Bench Test Procedure for a MT735, MTC735, MT745, MTC745, MT755, MTC755, MT765, and MTC765 Agricultural Tractor Transmission {3030, 3073} Caterpillar

Challenger

MT735 (S/N: AKN1-UP)

MT755 (S/N: ALM1-UP)

MT765 (S/N: AMS1-UP)

MTC735 (S/N: 8121-UP)

MTC745 (S/N: 8131-UP)

MTC755 (S/N: 8141-UP)

MTC765 (S/N: 8151-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS2644
02	Standardized.
01	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- specific transmission arrangements. 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. This 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:

• Cat Dealer Techinical Communicator

• Dealer Solution Network

• Cat Technical Representative

• Knowledge Network

Table 2

Machine Model	Transmission Arrangement
MT735	152-5241
MTC735	152-5241
MT745	152-5241
MTC745	152-5241
MT755	152-5241
MTC755	152-5241
MT765	152-5241
MTC765	152-5241

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 the test bench, use 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 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-9585	Block Gp Transmission Mounting Group	8
B	275-5213	Plate	1
C	439-3939	Link Bracket As	3
	7X-2562	Bolt (M20X2.5X45mm)	3
D	439-3940	Link Bracket As	2
	8T-4192	Bolt (M12X1.75X25mm)	2
E	1U-9722	Load Binder As (Ratchet Type)	4
F	165-0387	Yoke	1
G	4C-9032	Plate Adapter	1
H	9S-4181	Plug (Hex Head)	1
	7M-8485	O-Ring Seal	1
V	5P-9436	Plug (Hex Head)	1
	3D-2824	O-Ring Seal	1
J(1)	9W-1454	Cover	1
	6V-3966	Nipple Assembly	1
	5P-3863	O-Ring Seal	1
K(1)	9W-1454	Cover	1
	6V-3966	Nipple Assembly	1
	5P-3863	O-Ring Seal	1
L(1)	9W-1454	Cover	1
	6V-3966	Nipple Assembly	1
	5P-3863	O-Ring Seal	1
M	6V-3965	Fitting As (Quick Disconnect)	1
	4J-0524	O-Ring Seal	1
N	6V-3965	Fitting As (Quick Disconnect)	1
	4J-0524	O-Ring Seal	1
W	7M-8485	O-Ring Seal	1
	5P-0492	Adapter	1
	8C-9024	Fitting As (PLAIN)	1
P	7M-8485	O-Ring Seal	1
	5P-0492	Adapter	1
	7X-7646	Nipple Assembly (PLAIN)	1
	7D-0978	Tee (37 Flared)	1
	9S-8895	Plug	1
Q	7M-8485	O-Ring Seal	1
	5P-0492	Adapter	1
	1P-5598	Nipple (Pipe)	1
	5L-3785	Nipple	1
	5P-4495	Tee (37 Flared)	1
	6U-0464	Adapter (Swivel)	1
	004-7270	Nipple (Pipe)	1
	5P-0492	Adapter	1
	7X-7646	Nipple Assembly	1
R	9S-8895	Plug	1
	7D-0978	Tee (37 Flared)	1
	4C-8689	Flow meter	1
	5B-9892	Nipple (Pipe)	1
	267-8926	Valve (Needle)	1
	6U-0464	Adapter (Swivel)	1
S	9U-7500	Transmission Analyzer Tool Gp	1
	306-0397	Extension Cable	1
	9U-7496	Cable (TEST)	1
	1U-9480	Cable Adapter	9
T	9U-7400	Multitach Tool Gp	1
	211-1774	Adapter Cable As (Speed Sensor)	2
U	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	10
	8T-0862	Pressure Gauge (−100 to 500 kPa (−15 to 72 psi))	6
	8T-0854	Pressure Gauge (0 to 145 kPa (0 to 145 psi))	1
	6V-4144	Coupler	17

(1)	Refer to Illustration 1.

Illustration 3	g01179720

Installation Procedure

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Illustration 4	g06017374

1. Install Tooling (A) on the rails of the test bench.
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   Illustration 5	g06017377
   Input end of the transmission

2. Install Special Tooling (B) to the transmission.
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   Illustration 6	g06017380

3. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1177 kg (2596 lb).
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   Illustration 7	g06017382

4. Install Tooling (C) to the rear of the transmission.
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   Illustration 8	g06017387
   Input end of the transmission

5. Install Tooling (C) to the front of the transmission.
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   Illustration 9	g06017389

6. Install Tooling (D) to the rear of the transmission.
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   Illustration 10	g06017391

7. Install Tooling (E) to the front of the transmission.
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   Illustration 11	g06017396
   Output end of the transmission

8. Install Tooling (E) to the rear of the transmission.
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   Illustration 12	g06017401

9. Install Tooling (F) to the splined transmission input shaft.
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   Illustration 13	g06017402

10. Install Tooling (G) to Tooling (F).
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    Illustration 14	g06017405

11. Align the transmission with the input drive shaft.

12. Connect the input drive shaft to Tooling (G).
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    Illustration 15	g06017408

13. Install the drive shaft guard.
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    Illustration 16	g03375318

14. Tighten all four castle nuts and jack bolts.
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    Illustration 17	g06017413

15. Install Tooling (H).
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    Illustration 18	g06017370

16. Install Tooling (V).
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    Illustration 19	g06017422

17. Remove cover (1).
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    Illustration 20	g06017427

18. Install Tooling (J).
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    Illustration 21	g06017430

19. Remove cover (2).
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    Illustration 22	g06017431

20. Install Tooling (K).
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    Illustration 23	g06017433

21. Remove cover (3).
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    Illustration 24	g06017434

22. Install Tooling (L).
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    Illustration 25	g06017435

23. Remove plug (4).
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    Illustration 26	g06017436

24. Install Tooling (M).
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    Illustration 27	g06017439

25. Remove plug (5).
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    Illustration 28	g06017442

26. Install Tooling (N).
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    Illustration 29	g06017414

27. Install Tooling (W).
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    Illustration 30	g06017444

28. Install Tooling (P).
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    Illustration 31	g06017446

29. Install Tooling (Q).
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    Illustration 32	g06017448

30. Install Tooling (R).
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    Illustration 33	g06017449

31. Connect hose assembly (6) from Tooling (P) to Tooling (R).
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    Illustration 34	g06017451
    (7) Charge Pump Supply

32. Connect hose assembly (7) from the pressurized flow meter to Tooling (Q).
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    Illustration 35	g06017454
    (8) Cooler Supply

33. Connect hose assembly (8) from Tooling (W) to the No. 2 flow meter inlet.
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    Illustration 36	g06017456
    (9) Lubrication Oil Supply

34. Connect hose assembly (9) from the No. 2 flow meter outlet to Tooling (P).
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    Illustration 37	g06017459
    (10) Charge Pressure

35. Connect a pressure gauge to pressure tap (10).
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    Illustration 38	g06017462
    (11) Lubrication Bypass

36. Connect a pressure gauge to pressure tap (11).
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    Illustration 39	g06017468
    (12) Cooler Bypass

37. Connect pressure gauge (12) to Tooling (L).
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    Illustration 40	g06017470
    (13) Input Shaft Lubrication Pressure

38. Connect a pressure gauge to pressure tap (13).
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    Illustration 41	g06017473
    (14) Output Shaft Lubrication Pressure

39. Connect a pressure gauge to pressure tap (14).
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    Illustration 42	g06017477
    (15) Intermediate Shaft Pressure

40. Connect a pressure gauge to pressure tap (15).
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    Illustration 43	g06017479
    (16) Reverse Shaft Lubrication Pressure

41. Connect a pressure gauge to pressure tap (16).
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    Illustration 44	g06017480
    (17) Transmission Lubrication Pressure

42. Connect a pressure gauge to pressure tap (17).
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    Illustration 45	g06017481
    (26) No. 9 Clutch Control Pressure (23) No. 6 Clutch Control Pressure (18) No. 1 Clutch Control Pressure (19) No. 2 Clutch Control Pressure (20) No. 3 Clutch Control Pressure (21) No. 4 Clutch Control Pressure (22) No. 5 Clutch Control Pressure (24) No. 7 Clutch Control Pressure (25) No. 8 Clutch Control Pressure

43. Connect pressure gauges to pressure taps (18), (19), (20), (21), (22), (23), (24), (25), and (26).
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    Illustration 46	g06017482

44. Connect Tooling (S) to nine clutch solenoids.
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    Illustration 47	g06017484

45. Connect Tooling (S) to a suitable location.
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    Illustration 48	g00877510
    Tooling (S)

46. Connect Tooling (S) to a power source. Refer to Tool Operating Manual, NEHS0644 for the correct operating instructions.

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

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    Illustration 49	g06017487
    (27) Output Speed Sensor (A) ( 28) Output Speed Sensor (B)

47. Connect Tooling (T) to output speed sensors (A) and (B).

Test Procedure

Solenoid Test (TA2 only)

1. Make sure that the harness is properly connected.

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

3. Record the values in Table 6.

   Note: Do not continue testing until Solenoid Test passes.

Start Checks

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.
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   Illustration 50	g02720621

   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.

2. Adjust the supply flow to 120 L/min (32 US gpm).

3. The lubrication pressure must be minimum 137 kPa (20 psi).

4. Shift the transmission through all gears 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	Cl 8	Cl 9
   N								X
   F1	X				X
   F2		X			X
   F3			X		X
   F4				X	X
   R1					X				X
   R2						X			X
   R3							X		X
   R4								X	X

6. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 700 rpm.

7. Verify all test points with the values in Table 7.

8. Record the values in table 8.

   Note: Tooling (S) has been programmed to ensure that the transmission is shifted sequentially into gear ranges. The functionality of some of the input keys has been changed to ensure the requirements of this procedure. Refer to Special Instruction, "Programming Features" for further Information.

9. Stop the input rotation.

High Idle Checks

Note: Make all shifts from NEUTRAL at 1000 ± 10 rpm.

1. Adjust the inlet flow to 120 L/min (32 US gpm).

2. Adjust the input rotation to 2100 ± 10 rpm in the NEUTRAL position.

3. Record the pressures for the active clutches in Table 10.

4. Record the values in Table 10 for charge pressure, cooler flow, lubrication pressure, clutch leakages, shaft pressures, and output speed and 12 for clutch pressures.

   Note: Calculate clutch leakage by subtracting cooler flow from supply flow.

5. Verify the test points with the values in Tables 9 and 11.

6. Shift the transmission through each FORWARD and REVERSE speed range. Repeat steps 1 through 5 for each gear range.

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

7. Stop the input rotation.

Lubrication Bypass Check

1. Adjust the inlet flow to 120 L/min (32 US gpm).

2. Adjust the input rotation to 2100 ± 10 rpm.

3. Slowly adjust the oil supply to 215 L/min (57 US gpm) at tooling (R). At the same time monitor the lubrication bypass pressure.

4. The lubrication bypass pressure should stabilize at 275 ± 34 kPa (40 ± 5 psi).

5. Record the values in table 14.

6. Stop the input rotation.

Cooler Bypass Check

1. Adjust the inlet flow to 120 L/min (32 US gpm).

2. Adjust Tooling (R) to provide 12 L/min (3 US gpm) flow to the lubrication supply .

3. Adjust the input rotation to 2100 ± 10 rpm.

4. Slowly increase the restriction at the number 2 flow meter by adjusting the flow meter load valve clockwise until the cooler bypass pressure stabilizes.

5. The cooler bypass pressure should Stabilize at 34 kPa (75 ± 5 psi).

6. Record the values in table 16.

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 17.

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	Solenoid 3	Solenoid 4	Solenoid 5	Solenoid 6	Solenoid 7	Solenoid 8	Solenoid 9
	______ ohms	______ ohms	______ ohms	______ ohms	______ ohms	______ ohms	______ ohms	______ ohms	______ ohms

Start Checks

Table 7

Start Checks
Pump Flow And Pressures		Input Speed (700 ± 10 rpm) Input Flow 120 L/min (32 US gpm)
Gear	Supply Flow	Charge Pressure	Cooler Flow	Lubrication Pressure	Output Speed
F1	120 L/min (32 US gpm)	2102 ± 34 kPa (305 ± 5 psi)	105 L/min (28 US gpm)	172 ± 21 kPa (25 ± 3 psi)	334 rpm
N				214 ± 21 kPa (31 ± 3 psi)	0 rpm
R1				165 ± 21 kPa (24 ± 3 psi)	267 rpm

Table 8

Start Checks
Pump Flow And Pressures		Input Speed (1000 rpm) Input Flow (15 gpm)
Oil Temperature		°C (°F)
Gear	Supply Flow	Charge Pressure	Cooler Flow	Lubrication Pressure	Output Speed
F1	______________	______________	______________	______________	______________
N	______________	______________	______________	______________	______________
R1	______________	______________	______________	______________	______________

Clutch Pressures

Table 9

Clutch Pressures
Gear	Clutches		Cl 1	Cl 2	Cl 3	Cl 4	Cl 5	Cl 6	Cl 7	Cl 8	Cl 9
N	-	8								2102 ± 34 kPa (305 ± 5 psi)
F1	1	5	2102 ± 34 kPa (305 ± 5 psi)				2102 ± 34 kPa (305 ± 5 psi)
F2	2	5		2102 ± 34 kPa (305 ± 5 psi)			2102 ± 34 kPa (305 ± 5 psi)
F3	3	5			2102 ± 34 kPa (305 ± 5 psi)		2102 ± 34 kPa (305 ± 5 psi)
F4	4	5				2102 ± 34 kPa (305 ± 5 psi)	2102 ± 34 kPa (305 ± 5 psi)
R1	5	9					2102 ± 34 kPa (305 ± 5 psi)				2102 ± 34 kPa (305 ± 5 psi)
R2	6	9						2102 ± 34 kPa (305 ± 5 psi)			2102 ± 34 kPa (305 ± 5 psi)
R3	7	9							2102 ± 34 kPa (305 ± 5 psi)		2102 ± 34 kPa (305 ± 5 psi)
R4	8	9								2102 ± 34 kPa (305 ± 5 psi)	2102 ± 34 kPa (305 ± 5 psi)

Table 10

Clutch Pressures
Gear	Clutches		Cl 1	Cl 2	Cl 3	Cl 4	Cl 5	Cl 6	Cl 7	Cl 8	Cl 9
N	-	8								_____
F1	1	5	_____				_____
F2	2	5		_____			_____
F3	3	5			_____		_____
F4	4	5				_____	_____
R1	5	9					_____				_____
R2	6	9						_____			_____
R3	7	9							_____		_____
R4	8	9								_____	_____

High Idle Check

Table 11

High Idle Checks							Input Speed (2100 ± 10 rpm)
Gear	Supply Flow		Charge Pressure kPa (psi)		Cooler Flow L/min (gpm)		Lubrication Pressure kPa (psi)	Leakage
N	125 L/min (32 US gpm)		2100 ± 34 kPa (305 ± 5 psi)		102 ± 12 L/min (27 ± 3 US gpm)		193 ± 19 kPa (28 ± 3 psi)	11 ± 4 L/min (3 ± 1 US gpm)
F1							145 ± 14 kPa (21 ± 2 psi)
F2							145 ± 14 kPa (21 ± 2 psi)
F3							145 ± 14 kPa (21 ± 2 psi)
F4							145 ± 14 kPa (21 ± 2 psi)
R1							138 ± 14 kPa (20 ± 2 psi)
R2							138 ± 14 kPa (20 ± 2 psi)
R3							117 ± 14 kPa (17 ± 2 psi)
R4							110 ± 14 kPa (16 ± 2 psi)
Gear	Input Shaft Lubrication kPa (psi)		Reverse Shaft Lubrication kPa (psi)		Intermediate Shaft Lubrication kPa (psi)		Output Shaft Lubrication kPa (psi)	Output Speed rpm
N	207 ± 69 kPa (30 ± 10 psi)		207 ± 69 kPa (30 ± 10 psi)		207 ± 69 kPa (30 ± 10 psi)		207 ± 69 kPa (30 ± 10 psi)	12
F1	151 ± 27 kPa (22 ± 4 psi)		144 ± 27 kPa (21 ± 4 psi)		90 ± 27 kPa (13 ± 4 psi)		144 ± 27 kPa (21 ± 4 psi)	249
F2	151 ± 27 kPa (22 ± 4 psi)		151 ± 27 kPa (22 ± 4 psi)		103 ± 27 kPa (15 ± 4 psi)		144 ± 27 kPa (21 ± 4 psi)	315
F3	144 ± 27 kPa (21 ± 4 psi)		144 ± 27 kPa (21 ± 4 psi)		131 ± 27 kPa (19 ± 4 psi)		144 ± 27 kPa (21 ± 4 psi)	400
F4	151 ± 34 kPa (22 ± 5 psi)		144 ± 27 kPa (21 ± 4 psi)		138 ± 27 kPa (20 ± 4 psi)		144 ± 27 kPa (21 ± 4 psi)	507
R1	144 ± 27 kPa (21 ± 4 psi)		138 ± 27 kPa (20 ± 4 psi)		131 ± 27 kPa (19 ± 4 psi)		144 ± 27 kPa (21 ± 4 psi)	200
R2	144 ± 27 kPa (21 ± 4 psi)		138 ± 27 kPa (20 ± 4 psi)		131 ± 27 kPa (19 ± 4 psi)		138 ± 27 kPa (20 ± 4 psi)	486
R3	124 ± 27 kPa (18 ± 4 psi)		117 ± 21 kPa (17 ± 3 psi)		110 ± 21 kPa (16 ± 3 psi)		117 ± 21 kPa (17 ± 3 psi)	548
R4	110 ± 21 kPa (16 ± 3 psi)		110 ± 21 kPa (16 ± 3 psi)		103 ± 21 kPa (15 ± 3 psi)		110 ± 21 kPa (16 ± 3 psi)	1330

Table 12

High Idle Checks				Input Speed (2100 ± 10 rpm)
Gear	Supply Flow	Charge Pressure kPa (psi)	Cooler Flow L/min (gpm)	Lubrication Pressure kPa (psi)	Leakage
N
F1
F2
F3
F4
R1
R2
R3
R4
Gear	Input Shaft Lubrication kPa (psi)	Reverse Shaft Lubrication kPa (psi)	Intermediate Shaft Lubrication kPa (psi)	Output Shaft Lubrication kPa (psi)	Output Speed
N
F1
F2
F3
F4
R1
R2
R3
R4

Lubrication Bypass Check

Table 13

Lubrication Bypass
Lubrication Bypass Pressure	275 ± 34 kPa (40 ± 5 psi)

Table 14

Lubrication Bypass
Lubrication Bypass Check 275 ± 34 kPa (40 ± 5 psi)	_______kPa _______(psi)

Cooler Bypass Check

Table 15

Cooler Bypass
Cooler Bypass Pressure	517 ± 34 kPa (75 ± 5 psi)

Table 16

Cooler Bypass
Cooler Bypass Check 517 ± 34 kPa (75 ± 5 psi)	_______kPa _______(psi)

Contamination Control

Table 17

ISO Particle Count

Sample the test bench oil supply. *ISO 4406 is 16/13 or better

________/________Particle Count

Table 18

______________________________________ Technician

______________________________________ Supervisor