Bench Test Procedure for a 735B, 740B, and 740B Ejector Articulated Dump Truck Transmission{3030, 3073, 3139, 3167} Caterpillar

Articulated Truck:

735B (S/N: L4D1-UP; T4P1-UP)

740B (S/N: L4E1-UP; T4R1-UP)

740B EJECTOR (S/N: L4F1-UP; T4S1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS3608
03	Updated introduction. Updated Tooling in Table 3.
02	Updated introduction. Inserted "Think Safety" graphic. Updated Tooling in Table 3.
01	Updated graphics.

© 2015 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar 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 in order 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. In order to address an urgent need, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

• Cat Dealer Techinical Communicator

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Table 2

Machine Model	Transmission Arrangement
735B	303-2298
740B	303-2298
740B Ejector	303-2298

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information about Canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Collecting the Test Data

Since conditions vary for each test bench, use the data that is collected from your test bench. The collected data is used to compare test results. The data should be collected and maintained by the operator.

Data from each transmission arrangement is collected and stored. Averages from each transmission arrangement are often used in order 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.

Illustration 1	g02139237

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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 in order to develop this test procedure.

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9584	Rail As	2
	4C-9998	Bracket	2
	9U-6001	Crossmember	1
	1D-4614	Bolt (3/4-10X5.0 inch)	4
	5P-8248	Hard Washer	4
	2J-3506	Full Nut	4
	1U-9585	Block Gp	1
B	1U-5798	Drive Adapter Gp	1
C	4C-4701	Spindle Adapter	1
	2J-5245	Bolt (3/8-16X1.25 inch)	4
	3B-4506	Lockwasher	4
D	1U-5999	Spindle Gp	1
	0S-1587	Bolt (1/2-13X1.75 inch)	4
	3B-4508	Lockwasher	4
E	1U-6721	Adapter (Drive)	1
F	1U-9131	Drive Adapter (Key) (1)	1
G	1U-9359	Drive Adapter (2)	1
H	138-7575	Link Bracket	2
	1U-9722	Load Binder As (Ratchet Type)	3
J	4C-4898	Cover (Transmission Test)	1
K	9U-7444	Adapter	1
	7M-8485	O-Ring Seal	1
L	FT-2974	Adapter (Overflow)	1
	0S-1594	Bolt (3/8-16X1 inch)	3
	5M-2894	Hard Washer	3
M	6V-3137	Magnetic Base (Photo Pickup)	1
N	235-4764	Adapter	1
	8C-5212	O-Ring Seal	1
	140-5978	Fitting	1
	1U-9879	Fitting (Camlock fitting)	1
	0T-0573	Bolt (3/8-16X2.75 inch)	4
	5M-2894	Hard Washer	4
O	9U-7444	Adapter (Flange)	1
	1U-8301	Fitting (Flange)	1
	1P-4577	Half Flange	2
	8C-9024	Fitting As (Plain)	1
	6V-3965	Fitting As (Quick Disconnect)	1
	3J-1907	O-Ring Seal	1
	4J-0520	O-Ring Seal	1
	7M-8485	O-Ring Seal	1
	0S-1588	Bolt (3/8-16X1.25 inch)	4
	5M-2894	Hard Washer	4
P	9U-7445	Adapter	1
	1U-8301	Fitting	1
	1P-4578	Half Flange	2
	8C-9024	Fitting As (Plain)	1
	6V-3965	Fitting As (Quick Disconnect)	1
	3J-1907	O-Ring Seal	1
	4J-0522	O-Ring Seal	1
	7M-8485	O-Ring Seal	1
	1D-4707	Bolt (7/16-14X2.25 inch)	4
	5P-8244	Washer	4
Q	9U-7446	Adapter	1
	1U-8304	Fitting	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
	4J-0524	O-Ring Seal	1
	7M-8485	O-Ring Seal	1
	0S-1585	Bolt (1/2-13X1.50 inch)	4
	5P-8245	Hard Washer	4
R	9U-7446	Adapter	1
	1U-8304	Fitting	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
	4J-0524	O-Ring Seal	1
	7M-8485	O-Ring Seal	1
	1B-2886	Bolt (1/2-13X3.75 inch)	4
	5P-8245	Hard Washer	4
S	(3)	Fitting	1
	3B-7721	Reducer Bushing	1
	8T-3613	Fitting As	1
T	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	10
	6V-4144	Coupler	10
U	8T-0854	Pressure Gauge (0 to 1,000 kPa (0 to 145 psi))	1
	6V-4144	Coupler	1
V	8T-0862	Pressure Gauge (-100 to 500 kPa (-15 to 72 psi))	1
	6V-4144	Coupler	1
W	277-2362	Analyzer III Group	1
	306-0397	Extension Cable	1
	FT3206	Adapter Harness As	1
X (4)	146-4080	Digital Multimeter	1
	5P-5677	Electrical Wire	1
	155-2270	Connecting Plug Kit	1
	186-3736	Connector Socket	2
Y (4)	9U-7400	Multitach Tool Gp	1
	211-1774	Adapter Cable As (Speed Sensor)	2
Z (4)	120-6843	Ball or Gate Valve	1
	8C-9024	Nipple (Quick Disconnect)	1
	8C-9025	Coupler (Quick Disconnect)	1
	3B-7749	Nipple (Close)	1

( 1 )	This drive adapter is used with the small drive shaft.
( 2 )	This drive adapter is used with the large drive shaft.
( 3 )	Parker 8-3/8 AOEG
( 4 )	Tooling for checking speed sensor manually

Installation Procedure

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Illustration 2	g00959583

1. Install Tooling (A) on the rails of the test bench, as shown.

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Illustration 3	g00959585

2. Use a hoist to install the transmission on the test bench. The weight of the transmission is 1385 kg (3050 lb).

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Illustration 4	g00959586

3. Use a hoist to install Tooling (B) on the torque converter. The weight of tooling (B) is 24.5 kg (54 lb)

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Illustration 5	g00959588

4. Use a hoist to install Tooling (C) to the transmission case. The weight of tooling (C) is 39 kg (86 lb)

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Illustration 6	g00959590

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.

5. Use a hoist to install Tooling (D) on Tooling (C). The weight of tooling (D) is 121 kg (267 lb)

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Illustration 7	g00959592

6. Tighten the collet on Tooling (D) in order to connect Tooling (D) to Tooling (B) .

   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.

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Illustration 8	g00959598

7. Install Tooling (E) to the input shaft of Tooling (D) .

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Illustration 9	g00959599

8. Install Tooling (F) to the input shaft of Tooling (E) .

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

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Illustration 10	g00959600

9. Align the transmission with the input drive shaft.

10. Connect the input drive shaft to Tooling (F) .

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Illustration 11	g00959602

11. Install the drive shaft guard.

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Illustration 12	g02457316

12. Install Tooling (H) to the input and output end of the transmission.

13. Tighten all four castle nuts and jack bolts on the test bench bed.

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Illustration 13	g02722212

14. Install Tooling (J) after removing transmission cover.

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Illustration 14	g00959627

15. Remove plug (4) .

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Illustration 15	g00959629

16. Install Tooling (K) .

    Note: Tooling (K) will activate the drain valve, allowing the oil to drain into the test bench.

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Illustration 16	g00959631

17. Remove cover (5) .

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Illustration 17	g00959634

18. Install Tooling (L) .

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Illustration 18	g00959636

19. Remove cover (6) .

20. Remove the magnetic filter.

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Illustration 19	g00959639

21. Install Tooling (M) .

    Note: Tooling (M) will block the oil flow to the oil pan.

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Illustration 20	g00959642

22. Install Tooling (N) .

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Illustration 21	g00959644

23. Install Tooling (O) .

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Illustration 22	g02479956

24. Install Tooling (P) .

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Illustration 23	g00959649

25. Install Tooling (Q) .

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Illustration 24	g02722207

26. Install tooling (Z) .

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Illustration 25	g02480179

27. Install Tooling (R) .

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Illustration 26	g00959656

28. Cover Tooling (C). Use a suitable clean cover.

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Illustration 27	g00959658

29. Connect hose assembly (7) from the pump supply to Tooling (N) .

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Illustration 28	g00959660
Outlet for the Transmission Oil Pump

30. Connect hose assembly (8) from the No. 1 flow meter inlet to Tooling (O) .

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Illustration 29	g02722203

31. Connect hose assembly (9) from the outlet of the No. 1 flow meter to Tooling (P) .

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Illustration 30	g02722202
Converter Outlet

32. Connect hose assembly (10) from the No. 2 flow meter inlet to Tooling (Z) .

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Illustration 31	g02480398
Inlet for the Transmission Lubrication Oil

33. Connect hose assembly (11) from the outlet of the No. two flow meter to Tooling (R) .

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Illustration 32	g00959672

34. Connect lube line (12) from the test bench to Tooling (D). Maintain an oil pressure of 275 kPa (40 psi).

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Illustration 33	g02722199
(13) Pressure tap for the Torque converter inlet (14) Pressure tap for the Main Relief (15) Pressure tap for the No. 5 clutch (16) Pressure tap for the No. 3 clutch (17) Pressure tap for the No. 4 clutch (18) Pressure tap for the Lockup clutch (19) Pressure tap for the No. 1 clutch (20) Pressure tap for the No. 2 clutch (21) Pressure tap for the No. 7 clutch (22) Pressure tap for the No. 6 clutch

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

35. Connect Tooling (T) to pressure taps (13), (14), (15), (16), (17), (18), (19), (20), (21), and (22), as shown.

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Illustration 34	g00959682
Transmission Lubrication Pressure Tap

36. Connect Tooling (V) to Tooling (R) .

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Illustration 35	g02722198

37. Connect Tooling (W) to harness connector as shown.

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Illustration 36	g00959686

38. Connect Tooling (W) to a suitable location, as shown.

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

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Illustration 37	g02629190
Tooling (W)

40. Install Tooling (W). Refer to Tool Operating Manual, NEHS0966 for the correct operating instructions.

Test Procedure

Harness Test

1. Make sure that Tooling (W) is properly connected.

2. Use Tooling (W) to perform Harness Test.

   Note: If Harness Test fails, do not continue with the Testing Procedure.

3. Document if Harness Test passed or failed in Table 6.

Solenoid Test

1. Make sure that Tooling (W) is properly connected.

2. Use Tooling (W) to perform Harness Test.

3. Record the values in Table 7.

Speed Sensor Test

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Illustration 38	g02722193

Note: There is one input sensor to be tested.

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Illustration 39	g02482001

Note: There are two output speed sensors on rear end of transmission output shaft that must be tested and identified.

1. Connect Tooling (X) to input speed sensor (25) .

2. Use Tooling (X) to measure the resistance.

3. Connect Tooling (X) to output speed sensor (26) .

4. Use Tooling (X) to measure the resistance.

5. Connect Tooling (X) to output speed sensor (27) .

6. Use Tooling (X) to measure the resistance.

7. Record the values in Table 8.

8. Verify the test points with the values in Table 4.
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   Table 4

   Speed Sensor Test
   Sensor	Resistance
   	Minimum	Maximum
   Transmission Output Speed Sensor "A"	750 Ω	1500 Ω
   Transmission Output Speed Sensor "B"	750 Ω	1500 Ω
   Input Speed Sensor "C"	750 Ω	1500 Ω

Start Checks

Note: Refer to Testing and Adjusting, UENR0205, "735B, 740B, and 740B EJECTOR Articulated Trucks 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.

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Illustration 40	g02720621

2. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 600 ± 25 rpm.

3. Shift the transmission through all speed ranges to eliminate air from the transmission controls.

4. Check for lockup or excessive drag in all ranges.

5. Stop input rotation.

6. Use the following procedure to test the transmission.

Pump Flow Test

1. Adjust the input rotation to 600 ± 25 rpm in the NEUTRAL position.

2. Shift the transmission to the FORWARD 1 position.

3. Record the pump supply flow in Table 9.

4. Adjust the input rotation to 1950 ± 25 rpm.

5. Record the pump supply flow in Table 9.

6. Shift the transmission to the NEUTRAL position.

7. Adjust the input rotation to 600 ± 25 rpm.

Main Relief Pressure

1. Adjust the input rotation to 1950 ± 25 rpm in the NEUTRAL position.

2. Check the pressure for the main relief valve. The correct pressure must be 3100 ± 70 kPa (450 ± 10 psi).

3. Record the main relief pressure in Table 10.

4. Adjust the input rotation to 600 ± 25 rpm in the NEUTRAL position.

Torque Converter Inlet Relief Valve

1. Adjust the input rotation to 600 ± 25 rpm in the NEUTRAL position.

2. Shift the transmission to the FORWARD 1 position.

3. Adjust the input rotation until the pump supply flow is 38 ± 0.4 L/min (10 ± 0.10 US gpm). Maintain this flow during this check.

4. Momentarily block the lube flow.

5. The converter inlet pressure must be 930 ± 100 kPa (135 ± 15 psi).

6. Open the lube flow.

7. Shift the transmission to the NEUTRAL position.

8. Record the value in Table 11.

Lube Circuit Check

1. Adjust the input rotation to 600 ± 25 rpm in the NEUTRAL position.

2. Shift the transmission to the FORWARD 2 position.

3. Adjust the input rotation until the lube flow is 115 ± 4 L/min (30 ± 1 US gpm). Maintain this flow during this check.

4. The lube pressure must be within 7 kPa (1 psi) of the average for this arrangement. Reference is 121 ± 17 kPa (17.5 ± 2.5 psi).

5. Shift the transmission to the NEUTRAL position.

6. Adjust the input rotation to 600 ± 25 rpm.

7. Record the value in Table 12.

Lube Pressure Test

1. Adjust the input rotation to 600 ± 25 rpm in the NEUTRAL position.

2. Shift the transmission to the FORWARD 1 position.

3. Record the lube pressure in Table 13.

4. Record the lube flow in Table 13.

5. Shift the transmission to the NEUTRAL position.

6. Shift the transmission to the REVERSE 2 position.

7. Record the lube pressure in Table 13.

8. Record the lube flow in Table 13.

9. Adjust the input rotation to 1950 ± 25 rpm.

10. Record the lube pressure in Table 14.

11. Record the lube flow in Table 14.

12. Adjust the input rotation to 600 ± 25 rpm.

13. Shift the transmission to the NEUTRAL position.

14. Shift the transmission to the FORWARD 1 position.

15. Adjust the input rotation to 1950 ± 25 rpm.

16. Record the lube pressure in Table 14.

17. Record the lube flow in Table 14.

18. The lube pressure must be minimum 15 kPa (2.2 psi).

19. The lube flow must be minimum 39 L/min (10.3 US gpm).

20. Shift the transmission through positions FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, and FORWARD 7. Repeat Steps 16 through 17 for each gear range.

21. The lube pressure must be minimum 183 kPa (26.5 psi).

22. The lube flow must be minimum 147.6 L/min (39 US gpm).

23. Adjust the input rotation to 600 ± 25 rpm.

24. Shift the transmission to the NEUTRAL position.

25. Stop the input rotation.

Final Pressure Checks (High Idle)

1. Adjust the input rotation to 600 ± 25 rpm with the transmission in the NEUTRAL position.

2. Adjust the input rotation to 1950 ± 25 rpm.

3. Record the clutch pressure in Table 16.

4. Adjust the input rotation to 600 ± 25 rpm.

5. Shift the transmission through positions REVERSE 1 and REVERSE 2. Repeat Steps 2 through 4 for each gear range.

6. Shift the transmission to the NEUTRAL position.

7. Adjust the input rotation to 1950 ± 25 rpm.

8. Shift the transmission to the FORWARD 1 position.

9. Record the clutch pressure in Table 16.

10. Shift the transmission through positions FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, and FORWARD 7. Record the clutch pressure for each gear range.

11. Adjust the input rotation to 600 ± 25 rpm.

12. Shift the transmission to the NEUTRAL position.

13. Verify that the clutch pressures match the values in Table 15.

14. Stop the input rotation.

ISO Particle Count

1. Sample the test bench oil supply.

2. Record the particle count in Table 17.

Transmission Bench Test Data Sheet

Table 5

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

Table 6

Harness Test
PASS	FAIL

Table 7

Solenoid Test	Solenoid 1	Solenoid 2	Solenoid 3	Solenoid 4	Solenoid 5	Solenoid 6	Solenoid 7	Solenoid 8
	_____ ohms	_____ ohms	_____ ohms	_____ ohms	_____ ohms	_____ ohms	_____ ohms	_____ ohms

Speed Sensor Test

Table 8

Speed Sensor Test
Sensor	Resistance
Transmission Output Speed Sensor "A"	______________________ Ω
Transmission Output Speed Sensor "B"	______________________ Ω
Input Speed Sensor "C"	______________________ Ω

Pump Flow Test

Table 9

Pump Flow Test	Gear Range FORWARD 1
	600 ± 25	1950 ± 25
	L/min (gpm)	L/min (gpm)

Main Relief Pressure

Table 10

Main Relief Pressure

Input Speed (1950 ± 25 rpm) Gear Range NEUTRAL

kPa (psi)

Converter Inlet Relief Valve

Table 11

Converter Inlet Relief Valve

Pump Supply Flow 38 ± 0.4 L/min (10 ± 0.10 US gpm) Gear Range FORWARD 1

Converter Outlet Pressure

kPa (psi)

Lube Circuit Check

Table 12

Lube Circuit Check		Gear Range FORWARD 2 Output Flow 114 ± 4 L/min (30 ± 1 US gpm)
Average Lube Pressure Of Arrangement	kPa (psi)	Lube Pressure	kPa (psi)

Lube Pressure Check (Low Idle)

Table 13

Lube Pressure Check (Low Idle)	Input Speed (600 ± 25 rpm)
Gear Range	Lube Pressure	Lube Flow
REVERSE 2	kPa (psi)	L/min (US gpm)
FORWARD 1	kPa (psi)	L/min (US gpm)

Lube Pressure Check (High Idle)

Table 14

Lube Pressure Check (High Idle)	Input Speed (1950 ± 25 rpm)
Gear Range	Lube Pressure	Lube Flow
REVERSE 2	kPa (psi)	L/min (US gpm)
FORWARD 1	kPa (psi)	L/min (US gpm)
FORWARD 2	kPa (psi)	L/min (US gpm)
FORWARD 3	kPa (psi)	L/min (US gpm)
FORWARD 4	kPa (psi)	L/min (US gpm)
FORWARD 5	kPa (psi)	L/min (US gpm)
FORWARD 6	kPa (psi)	L/min (US gpm)
FORWARD 7	kPa (psi)	L/min (US gpm)

Final Pressure Checks (High Idle)

Table 15

Final Clutch Pressure (High Idle)
Callout No.		"16"	"19"	"20"	"18"	"15"	"17"	"22"	"21"
Clutch		No. 3 (1)	No. 1 (1)	No. 2 (1)	LUC (2)	No. 5 (1)	No. 4 (1)	No. 6 (1)	No. 7 (1)
Speed Range	Engaged Clutches	Pressure
R2	3 and 7	1930 kPa (280 psi)							3102 kPa (450 psi)
R1	1 and 7		3102 kPa (450 psi)						3102 kPa (450 psi)
N	1		3102 kPa (450 psi)
1	2 and 6			1999 kPa (290 psi)	2082 kPa (302 psi)			2999 kPa (435 psi)
2	1 and 6		3033 kPa (440 psi)					2999 kPa (435 psi)
3	3 and 6	1930 kPa (280 psi)						2999 kPa (435 psi)
4	1 and 5		3033 kPa (440 psi)			2206 kPa (320 psi)
5	3 and 5	1896 kPa (275 psi)				2137 kPa (310 psi)
6	1 and 4		3033 kPa (440 psi)				1551 kPa (225 psi)
7	3 and 4	1896 kPa (275 psi)					1551 kPa (225 psi)

( 1 )	The tolerance is ± 207 kPa (± 30 psi).
( 2 )	The tolerance is ± 207 kPa (± 30 psi).

Table 16

Final Pressure Checks (High Idle)					Input Speed (1950 ± 25 rpm)
Callout No.			16	19	20	18	15	17	22	21
Clutch			3	1	2	LUC	5	4	6	7
Gear Range	Active Clutches		Pressures
R2	3	7
R1	1	7
N	1	-
1	2	6
2	1	6
3	3	6
4	1	5
5	3	5
6	1	4
7	3	4

ISO Particle Count

Table 17

ISO Particle Count

Sample the test bench oil supply.

________/________Particle Count

Table 18

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