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Bench Test Procedure for a 797 and 797B Off-Highway Truck Transmission {3030, 3073, 3139} Caterpillar


Bench Test Procedure for a 797 and 797B Off-Highway Truck Transmission {3030, 3073, 3139}

Usage:

797 5YW
Off-Highway Truck/Tractor
797 (S/N: 5YW1-UP)
797B (S/N: JSM1-UP)

Introduction

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Table 1
Revision  Summary of Changes in REHS1346 
08  Updated Tables 18 and 25. 
07  Added Tables 18, 20, and 25. 
Standardized.
06  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 procedure 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 Technical Communicator

  • Dealer Solution Network

  • Cat Technical Representative

  • Knowledge Network

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Table 2
Machine Model  Transmission Arrangement 
797  140-7002 
797B  140-7002 

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

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Illustration 1g02139237

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.

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Illustration 2g00008666

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 "NOT" 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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------ WARNING! ------

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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------ WARNING! ------

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

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------ WARNING! ------

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: The required tools that are listed in Table 3 were used to develop this test procedure. For additional information about tooling, consult Caterpillar Service Tools Division (800) 542-8665.

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Table 3
Required Tools 
Tool  Part Number  Part Description  Qty 
A  (1)  Support  1 
9X-8889 Bolt (3/4-10X3.5 inch)  16 
5P-8248 Hard Washer  16 
8H-5772 Bolt (1.0-8X3.75 inch)  20 
2J-3507 Full Nut  20 
5P-8250 Washer  40 
8C-3236 Bolt (M30X3.5X160 mm)  20 
9X-8399 Washer  20 
B  (1)  Drive Adapter  1 
230-4325 Bolt (M22X1.5X50 mm)  4 
0S-1595 Bolt (1/2-13X1.25 inch)  4 
5P-8245 Hard Washer  4 
C  (1)  Adapter  1 
0S-1587 Bolt (1/2-13X1.50 inch)  12 
5P-8245 Hard Washer  12 
D  (1)  Support (Output Shaft)  1 
1A-8063 Bolt (3/4-10X2.50 inch)  8 
5P-8248 Hard Washer  8 
E  472-0531  Hose As  1 
F  472-0555  Hose As  1 
G  472-0532  Hose As  1 
H  472-0535  Hose As  1 
8T-0273 Bolt (M12X1.75X40 mm)  2 
8T-4223 Hard Washer  2 
X  472-0537  Hose As  1 
095-0705 Bolt (M16X2.0X100 mm)  4 
9X-8268 Washer  4 
J  472-0534  Hose As  1 
8T-7811 Bolt (M12X1.75X50 mm)  4 
5C-8815 Washer  4 
K  472-0539  Hose As  1 
8T-0273 Bolt (M12X1.75X40 mm)  4 
5C-8815 Washer  4 
L  472-0536  Hose As  1 
095-0705 Bolt (M12X1.75X100 mm)  4 
9X-8268 Washer  4 
M  472-0538  Hose As  1 
N  472-0533  Hose As  1 
Y  8T-0855  Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))  7 
6V-3989 Fitting (Test)  7 
177-7861 Hose As  7 
6V-4143 Coupler  14 
P  9U-7500  Transmission Analyzer Tool Gp  1 
OR
277-2362 Transmission Analyzer Gp  1 
(1) Adapter Cable As  1 
Q  (1)  Data Acquisition System  1 
R  (1)  Pressure Transducer (0 to 4137 kPa (0 to 600 psi))  5 
S  (1)  Pressure Transducer (0 to 6895 kPa (0 to 1000 psi))  2 
T  (1)  Adapter (Sensor)  1 
U  146-4080  Digital Multimeter (RS-232)  1 
V  (2)  Vibration Data Capture System  1 
W  188-0645  Particle Analyzer Gp  1 
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(1) Contact Caterpillar Service Technology Group (309) 636-1675
(2) Contact Caterpillar Technical Services Division (309) 578-9194

Software Requirement

The 9U-7500 Electronic Control Group requires a custom software update to test the transmission for a 797 and 797B Off-Highway Truck. This software will not be included with the Software Subscription, NETG5021, "9U-7500 Transmission Analyzer II Program". You must order Software Update, NETG5036, "797 and 797B Transmission Analyzer II Program".

Programming Features

The 797 and 797B transmission must be shifted sequentially through the gear ranges.

The 9U-7500 Electronic Control Group has been programmed to ensure that the transmission will be shifted sequentially through the gears. The functionality of some of the input keys has been changed to ensure the requirements of this procedure. The following examples are typical screen displays.

The available keys will be listed across the bottom of the active display screen.

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Illustration 3g00928732

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Use the "FWD" key to shift the transmission to FORWARD 1.

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Use the "REV" key to shift the transmission to REVERSE 1.

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Use the "8" key to turn off the transmission harness, and use the "8" key to turn on the transmission harness.

Note: The "8" key is used to test the latching circuit. This function will simulate a power failure at the ECM.

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Use the "6" key to simulate an open circuit to a rear planetary clutch.

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Use the "4" key to simulate an open circuit to a front planetary clutch.

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Illustration 4g00878493

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Use the "N" key to shift the transmission to NEUTRAL.

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Illustration 5g00928736

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Use the "UP CURSOR" key to upshift the transmission to the next higher gear range.

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Illustration 6g00928740

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Use the "DOWN CURSOR" key to downshift the transmission to the next lower gear range.

Installation Procedure

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    Illustration 7g00924816

  1. Use a hoist to install Tooling (A) on the test bench. The weight of Tooling (A) is approximately 28 (6300 lb).
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    Illustration 8g00948434

  2. Use a hoist to install the transmission on Tooling (A). The approximate weight of the transmission is 62 (13800 lb).

  3. Install 20 bolts (1). Do not install the bolts next to each other. Skip a mounting hole for each bolt. The correct torque is 1600 ± 200 (1180 ± 148 lb ft).
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    Illustration 9g00948435

  4. Install Tooling (B) to the input yoke.
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    Illustration 10g00948436

  5. Align the transmission with the input drive shaft.

  6. Connect the input drive shaft to Tooling (B).
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    Illustration 11g00948439

  7. Install the drive shaft guard.
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    Illustration 12g00948440

  8. Install the extension for the drive shaft guard.
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    Illustration 13g00948441

  9. Use a hoist to install Tooling (C). The weight of Tooling (C) is (187 lb).
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    Illustration 14g00948442

  10. Use a hoist to install Tooling (D). The weight of Tooling (D) is 5 (1210 lb).
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    Illustration 15g00948446

  11. Connect Tooling (E) to the auxiliary oil tank.
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    Illustration 16g00948447

  12. Connect Tooling (E) to the test bench.
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    Illustration 17g00948448
    "Bearing Lub"

  13. Connect Tooling (F) to the auxiliary oil tank.
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    Illustration 18g00948449

  14. Connect Tooling (F) to Tooling (D). Maintain an oil pressure of 275 (40 psi).
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    Illustration 19g00948452

  15. Install Tooling (G) on the transmission.
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    Illustration 20g00948453

  16. Remove ecology drain (2).
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    Illustration 21g00948454

  17. Install Tooling (H).
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    Illustration 22g00948456

    Note: Tooling (H) is used as a sight gauge.

  18. Insert Tooling (H) into bolt hole.
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    Illustration 23g03323628
    "Transmission Control Supply"

  19. Connect Tooling (X) to the auxiliary oil tank.
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    Illustration 24g03323630

  20. Connect Tooling (X) to the transmission.
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    Illustration 25g00948460
    "Transmission Lube Supply"

  21. Connect Tooling (J) to the auxiliary oil tank.
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    Illustration 26g00948461

  22. Connect Tooling (J) to the transmission.
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    Illustration 27g00948462
    "Transmission Control Return"

  23. Connect Tooling (K) to the auxiliary oil tank.
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    Illustration 28g00948463

  24. Connect Tooling (K) to the transmission.
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    Illustration 29g00948464
    "Scavenge Inlet"

  25. Connect Tooling (L) to the auxiliary oil tank.
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    Illustration 30g00948467

  26. Connect Tooling (L) to the transmission.
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    Illustration 31g00948468

  27. Install Tooling (M) on the transmission.
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    Illustration 32g00948469

  28. Install Tooling (N) on the transmission.
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    Illustration 33g00948471
    (3) Pressure tap "CLUTCH 7"
    (4) Pressure tap "CLUTCH 4"
    (5) Pressure tap "CLUTCH 5"
    (6) Pressure tap "CLUTCH 6"
    (7) Pressure tap "CLUTCH 1"
    (8) Pressure tap "CLUTCH 3"
    (9) Pressure tap "CLUTCH 2"

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

  29. Connect Tooling (Y) to pressure taps (3), (4), (5), (6), (7), (8), and (9).
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    Illustration 34g00948472

  30. Connect Tooling (P) to the transmission harness.

    Note: The following Steps are for connecting Tooling (Q) to the transmission.

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    Illustration 35g00948475
    Tooling (Q)
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    Illustration 36g00987122

  31. Open the front panel of the test bench.
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    Illustration 37g00987123

  32. Connect signal cable (10) and signal cable (11) to the test bench.
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    Illustration 38g00948479
    (10) "Pressure 13" Horsepower from the Hydraulic Test Bench
    (11) "Pressure 14" Input Speed from the Hydraulic Test Bench

  33. Connect signal cable (10) and signal cable (11) to Tooling (Q).
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    Illustration 39g00948481
    Control Return Flow

  34. Connect signal cable (12) to the control panel for the auxiliary oil tank.
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    Illustration 40g00948482
    (12) "Flow 4" For The Transmission Control Return Flow

  35. Connect signal cable (12) to Tooling (Q).
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    Illustration 41g00948486
    Control Supply Flow

  36. Connect signal cable (13) to the control panel for the auxiliary oil tank.
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    Illustration 42g00948488
    (13) "Flow 3" Input Flow For The Transmission Control

  37. Connect signal cable (13) to Tooling (Q).
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    Illustration 43g00948492
    Lube Supply Flow

  38. Connect signal cable (14) to the control panel for the auxiliary oil tank.
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    Illustration 44g00948494
    (14) "Flow 2" Flow For Transmission Lubrication Oil

  39. Connect signal cable (14) to Tooling (Q).
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    Illustration 45g00948495

  40. Connect signal cable (15) to Tooling (D).
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    Illustration 46g00948499
    (15) "Flow 8" For The Output Speed

  41. Connect signal cable (15) to Tooling (Q).
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    Illustration 47g00948503
    Latching Pressure

  42. Connect Tooling (R) to the pressure tap for the transmission clutch latching pressure.

  43. Connect signal cable (16) to Tooling (R).
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    Illustration 48g00948506
    (16) "Pressure 6" Transmission Clutch Latching Pressure

  44. Connect signal cable (16) to Tooling (Q).
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    Illustration 49g00948508
    Transmission Control Return Pressure

  45. Connect Tooling (S) to the pressure tap for the transmission control return pressure.

  46. Connect signal cable (17) to Tooling (S).
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    Illustration 50g00948510
    (17) "Pressure 10" Transmission Control Return Pressure

  47. Connect signal cable (17) to Tooling (Q).
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    Illustration 51g00948513
    Lubrication Pressure (Rear Module)

  48. Connect Tooling (R) to the pressure tap for the rear module lube pressure.

  49. Connect signal cable (18) to Tooling (R).
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    Illustration 52g00948518
    (18) "Pressure 3" Lubrication Pressure (Rear Module)

  50. Connect signal cable (18) to Tooling (Q).
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    Illustration 53g00948519
    Pressure For The Transmission Lubrication Oil

  51. Connect Tooling (R) to the pressure tap for the transmission lubrication oil.

  52. Connect signal cable (19) to Tooling (R).
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    Illustration 54g00948522
    (19) "Pressure 2" Pressure For The Transmission Lubrication Oil

  53. Connect signal cable (19) to Tooling (Q).
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    Illustration 55g00948523
    Flow Meter For The Lubrication Flow (Front Module)

  54. Connect signal cable (20) to Tooling (G).
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    Illustration 56g00948525
    (20) "Flow 1" Lubrication Flow (Front Module)

  55. Connect signal cable (20) to Tooling (Q).
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    Illustration 57g00948527
    Lubrication Pressure (Front Module)

  56. Connect Tooling (R) to the pressure tap for the lubrication pressure (front module).

  57. Connect signal cable (21) to Tooling (R).
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    Illustration 58g00948528
    (22) "Pressure 5" Lubrication Pressure (Front Module)

  58. Connect signal cable (21) to Tooling (Q).
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    Illustration 59g00948531
    Transmission Control Supply Pressure

  59. Connect Tooling (R) to the pressure tap for the transmission control supply pressure.

  60. Connect signal cable (22) to Tooling (R).
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    Illustration 60g00948535
    (22) "Pressure 1" Transmission Control Supply Pressure

  61. Connect signal cable (22) to Tooling (Q).
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    Illustration 61g00948536
    Flow Meter For The Lockup Clutch Oil

  62. Connect signal cable (23) to Tooling (M).
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    Illustration 62g00948538
    (23) "Flow 5" Lockup Supply Flow

  63. Connect signal cable (23) to Tooling (Q).
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    Illustration 63g00948542
    Lockup Supply Pressure

  64. Connect Tooling (S) to Tooling (M).

  65. Connect signal cable (24) to Tooling (S).
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    Illustration 64g00948544
    (24) "Pressure 15" Lockup Supply Pressure

  66. Connect signal cable (24) to Tooling (Q).
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    Illustration 65g00948546
    (25) "Flow 7" Input For The Intermediate Speed Sensor

  67. Connect signal cable (25) from Tooling (P) to Tooling (Q).
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    Illustration 66g00953520
    (26) "Lube Pressure"
    (27) "Lube Temp"
    (28) "Latch Pressure"

    Note: Tooling (T) and Tooling (U) are used to measure the duty cycle of three internal sensors.

  68. Connect signal cables (26), (27), and (28) from Tooling (P) to Tooling (T).
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    Illustration 67g00987124

  69. Connect Tooling (U) to Tooling (T).
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    Illustration 68g00948550
    (29) Signal Cables
    (30) "Channe 1l"
    (31) "Channel 2"
    (32) "Channel 3"
    (33) "Channel 4"
    (34) "Channel 5"
    (35) "Channel 6"

  70. Connect six signal cables (29) to Tooling (V).
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    Illustration 69g00948551
    (30) "Channel 1"
    (31) "Channel 2"
    (32) "Channel 3"
    (33) "Channel 4"
    (34) "Channel 5"
    (35) "Channel 6"
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    Illustration 70g00948555
    (30) "Channel 1"

    Note: The accelerometers must be placed in the locations. Ensure that the accelerometer is mounted on a stable surface. Refer to Illustration 70 for additional information.

  71. Install the "Channel 1" accelerometer (30) to the transmission case.
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    Illustration 71g00948556
    (31) "Channel 2"

  72. Install the "Channel 2" accelerometer (31) to the transmission case.
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    Illustration 72g00948558
    (32) "Channel 3"

  73. Install the "Channel 3" accelerometer (32) to the transmission case.
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    Illustration 73g00948561
    (33) "Channel 4"

  74. Install the "Channel 4" accelerometer (33) to the transmission case.
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    Illustration 74g00948565
    (34) "Channel 5"

  75. Install the "Channel 5" accelerometer (34) to the transmission case.
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    Illustration 75g00948568
    (35) "Channel 6"

  76. Install the "Channel 6" accelerometer (35) to the transmission case.
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    Illustration 76g00948569
    (W) Portable S2 Particle Analyzer
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    Illustration 77g00948570

  77. Connect Tooling (W) to the transmission.
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    Illustration 78g00877510
    Tooling (P)
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    Illustration 79g01457869
    Tooling (P)

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

Test Procedure

Note: The transmission main relief valve MUST BE tested before the transmission can be tested. Refer to Special Instruction, RENR1347, "Bench Test Procedure For The 797 and 797B Off-Highway Truck Transmission Main Relief Valve and Torque Converter Relief Valves".

TA3 Navigation

  1. Select “Off-Highway Trucks”.

  2. Select “797–24V”.

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 8.

    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 8.

    Note: Do not continue testing until Solenoid Test passes.

Start Checks

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Table 4
Oil Requirements For Test Bench 
Oil Viscosity  SAE 10W 
Oil Temperature  (120 °F) to (130 °F) 
ISO Particle Count  16/13 

    Note: Refer to Specification, RENR2605, "797 Off-Highway Truck Power Train", Systems Operation, RENR2606, "797 Off-Highway Truck Power Train", and Testing and Adjusting, RENR2607, "797 Off-Highway Truck Power Train" for additional information.

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    NOTICE

    Never rotate the transmission in the state of no clutch neutral, rear box neutral, or multiple clutch tie up. Operating the transmission in any of these conditions can damage internal parts of the transmission.

    The transmission must be operated with the correct clutches engaged or disengaged to prevent damage to the transmission.

  1. Warm the supply oil in the auxiliary oil tank to (125 °F). Refer to the documentation that is provided with your equipment.

    Note: Multigrade oil is NOT permitted.

  2. The input rotation MUST BE 0 rpm.

  3. Adjust the input flow for the transmission control to 120 ± 4 L (31 ± 1 US gpm).

  4. Adjust the input flow for the transmission lubrication oil to 245 ± 4 L (65 ± 1 US gpm).

  5. Verify test points with the values in Table 9 before proceeding with the test.

    Note: Tooling (P) 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.

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    Illustration 80g02720621

  6. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 400 ± 10 rpm. Make all shifts at 400 ± 10 rpm during this test procedure.

    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.

    Use Tooling (P) to shift the transmission through all directions and through all speed ranges to eliminate air from the transmission controls.

  7. Verify that the active clutches are correct for each gear range. Refer to Table 5.

    Note: The active clutches must match Table 5 before proceeding with the test.

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    Table 5
    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       

  1. Adjust the input rotation to 400 ± 10 rpm.

  2. Shift the transmission to REVERSE.

  3. Adjust the input rotation to 700 ± 10 rpm.

  4. Record the values in Table 12.

  5. Verify test points with the values in Table 11 before proceeding with the test.

  6. Adjust the input rotation to 400 ± 10 rpm.

  7. Shift the transmission to NEUTRAL.

  8. Adjust the input rotation to 700 ± 10 rpm.

  9. Record the values in Table 12.

  10. Verify test points with the values in Table 11 before proceeding with the test.

  11. Adjust the input rotation to 400 ± 10 rpm.

  12. Shift the transmission to FORWARD 1.

  13. Adjust the input rotation to 700 ± 10 rpm.

  14. Record the values in Table 12.

  15. Verify test points with the values in Table 11 before proceeding with the test.

  16. Adjust the input rotation to 400 ± 10 rpm.

  17. Shift the transmission to the next gear range. Repeat Steps 13 through 16 for each forward gear range.

  18. Adjust the input rotation to 400 ± 10 rpm.

  19. Shift the transmission to NEUTRAL.

Warmup

    Note: Always adjust the input rotation to 400 rpm before you shift the transmission.

  1. Shifts at 400 ± 10 rpm then adjust the input rotation to 700 ± 10 rpm.

    Note: Wait for 3 seconds before you shift the transmission into the next gear range.

  2. Shift the transmission through all directions and through all speed ranges.

  3. Repeat Step 2 until the temperature of the transmission lubrication oil is between (120 °F) and (130 °F).

Latching Test (Zero Speed With Lockup)

    Note: Tooling (P) 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.

  1. Adjust the input flow for the transmission control to 326 ± 4 L (86 ± 1 US gpm).

  2. Adjust the input flow for the transmission lubrication oil to 633 ± 4 L (167 ± 1 US gpm).

  3. Adjust the input rotation to 0 rpm in NEUTRAL.

  4. Shift the transmission to FORWARD 1.

  5. Verify that the active clutches are correct for each gear range. Refer to Table 5.

  6. Record the values in Table 14.

  7. Verify test points with the values in Table 13.

  8. Press the "8" key to turn off the transmission harness. This function will simulate a harness failure.

  9. Verify that the active clutches are correct for each gear range. Refer to Table 5.

  10. Record the values in Table 14.

  11. Verify test points with the values in Table 13.

  12. Press the "8" key to turn on the transmission harness. This function will return the harness to normal operation.

  13. Verify test points with the values in Table 13.

  14. Shift the transmission to the next forward gear range. Repeat Steps 9 through 12 for each forward gear range.

  15. Shift the transmission to NEUTRAL.

Latching Test (Front And Rear Modules)

    Note: Tooling (P) 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.

  1. Adjust the input flow for the transmission control to 121 ± 4 L (32 ± 1 US gpm).

  2. Adjust the input flow for the transmission lubrication oil to 246 ± 4 L (65 ± 1 US gpm).

  3. Adjust the input rotation to 400 ± 10 rpm in NEUTRAL.

    Note: The following steps are for checking the transmission clutch latching for the front module for each gear.

  4. Shift the transmission to FORWARD 1.

  5. Adjust the input rotation to 700 ± 10 rpm.

  6. Verify that the active clutches are correct for each gear range. Refer to Table 5.

  7. Record the values in Table 16.

  8. Verify test points with the values in Table 15.

  9. Press key "4". This function will simulate a latched condition to the clutches for the front module.

  10. Verify test points with the values in Table 15.

    Note: The values in Table 15 must be present within 0.2 seconds.

  11. Press key "4". This will return the clutches for the front module to an unlatched condition.

  12. Record the values in Table 16.

  13. Verify test points with the values in Table 15.

  14. Adjust the input rotation to 400 ± 10 rpm.

  15. Shift the transmission to the next forward gear range. Repeat Steps 5 through 15 for each forward gear range.

  16. Adjust the input rotation to 400 ± 10 rpm.

  17. Shift the transmission to NEUTRAL.

    Note: The following steps are for checking the transmission clutch latching for the rear module for each gear.

  18. Shift the transmission to FORWARD 1.

  19. Adjust the input rotation to 700 ± 10 rpm.

  20. Verify that the active clutches are correct for each gear range. Refer to Table 5.

  21. Record the values in Table 16.

  22. Verify test points with the values in Table 15.

  23. Press key "6". This function will simulate a latched condition to the clutches for the rear module.

  24. Verify test points with the values in Table 15.

    Note: The values in Table 15 must be present within 0.2 seconds.

  25. Press key "6". This will return the clutches for the rear module to an unlatched condition.

  26. Record the values in Table 16.

  27. Verify test points with the values in Table 15.

  28. Adjust the input rotation to 400 ± 10 rpm.

  29. Shift the transmission to the next forward gear range. Repeat Steps 19 through 29 for each forward gear range.

  30. Adjust the input rotation to 400 ± 10 rpm.

  31. Shift the transmission to NEUTRAL.

Capturing The Vibration Data

    Note: Tooling (P) 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.The necessity of the vibration testing has been eliminated by quality improvements. This test will remain an optional test, but will no longer be supported by Cat Service Tools.Vibration data will be collected during this procedure. Refer to the documentation that is provided with your equipment for additional information.

  1. Adjust the input flow for the transmission control to 121 ± 4 L/min (32 ± 1 US gpm).

  2. Adjust the input flow for the transmission lubrication oil to 246 ± 4 L/min (65 ± 1 US gpm).

  3. Adjust the input rotation to 400 ± 10 rpm in NEUTRAL.

  4. Shift the transmission to REVERSE.

  5. Adjust the input rotation to 700 ± 10 rpm.

  6. Use Tooling (V) to capture the vibration data.

  7. Adjust the input rotation to 400 ± 10 rpm.

  8. Shift the transmission to NEUTRAL.

  9. Adjust the input rotation to 700 ± 10 rpm.

  10. Use Tooling (V) to capture the vibration data.

  11. Adjust the input rotation to 400 ± 10 rpm.

  12. Shift the transmission to FORWARD 1.

  13. Adjust the input rotation to 700 ± 10 rpm.

  14. Use Tooling (V) to capture the vibration data.

  15. Adjust the input rotation to 400 ± 10 rpm.

  16. Shift the transmission to the next gear range. Repeat Steps 13 through 16 for each forward gear range.

  17. Verify that all channels pass.

  18. Adjust the input rotation to 400 ± 10 rpm.

  19. Shift the transmission to NEUTRAL.

  20. Adjust the input flow for the transmission control to 227 ± 2 L/min (60 ± 0.5 US gpm).

  21. Adjust the input flow for the transmission lubrication oil to 458 ± 2 L/min (121 ± 0.5 US gpm).

  22. Adjust the input rotation to 400 ± 10 rpm in NEUTRAL.

    Note: Always adjust the input rotation to 400 rpm before you shift the transmission.

  23. Shift the transmission to REVERSE.

  24. Adjust the input rotation to 1300 ± 10 rpm.

  25. Use Tooling (V) to capture the vibration data.

  26. Adjust the input rotation to 400 ± 10 rpm.

  27. Shift the transmission to NEUTRAL.

  28. Adjust the input rotation to 1300 ± 10 rpm.

  29. Use Tooling (V) to capture the vibration data.

  30. Adjust the input rotation to 400 ± 10 rpm.

  31. Shift the transmission to FORWARD 1.

  32. Adjust the input rotation to 1300 ± 10 rpm.

  33. Use Tooling (V) to capture the vibration data.

  34. Adjust the input rotation to 400 ± 10 rpm.

  35. Shift the transmission to the next gear range. Repeat Steps 32 through 35 for each forward gear range.

  36. Verify that all channels pass.

  37. Adjust the input rotation to 400 ± 10 rpm.

  38. Shift the transmission to NEUTRAL.

Medium Idle Checks

    Note: Always adjust the input rotation to 400 rpm before you shift the transmission.

  1. Adjust the input flow for the transmission control to 227 ± 2 L/min (60 ± 0.5 US gpm).

  2. Adjust the input flow for the transmission lubrication oil to 458 ± 2 L/min (121 ± 0.5 US gpm).

  3. Adjust the input rotation to 400 ± 10 rpm.

  4. Shift the transmission to REVERSE.

  5. Adjust the input rotation to 1300 ± 10 rpm.

  6. Record the values in Table 21.

  7. Verify test points with the values in Table 17.

    Note: Verify test points with values in Table 18 if the transmission has been updated per SMAG SEPD1916 or SMAG M0064316.

  8. Adjust the input rotation to 400 ± 10 rpm.

  9. Shift the transmission to NEUTRAL.

  10. Shift the transmission to FORWARD 1.

  11. Adjust the input rotation to 1300 ± 10 rpm.

  12. Record the values in Table 21.

  13. Verify test points with the values in Table 17.

    Note: Verify test points with values in Table 18 if the transmission has been updated per SMAG SEPD1916 or SMAG M0064316.

  14. Adjust the input rotation to 400 ± 10 rpm.

  15. Shift the transmission to the next gear. Repeat Steps 11 through 15 FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, FORWARD 6, and FORWARD 7.

  16. Adjust the input rotation to 400 ± 10 rpm.

  17. Shift the transmission through gear ranges FORWARD 6, FORWARD 5, FORWARD 4, FORWARD 3, FORWARD 2, FORWARD 1, and NEUTRAL.

High Idle Checks

    Note: Always adjust the input rotation to 400 rpm before you shift the transmission.

  1. Adjust the input flow for the transmission control to 326 ± 2 L/min (86 ± 0.5 US gpm).

  2. Adjust the input flow for the transmission lubrication oil to 632 ± 2 L/min (167 ± 0.5 US gpm).

  3. Adjust the input rotation to 400 ± 10 rpm.

    Note: Do not test FORWARD 7 in this procedure.

  4. Shift the transmission to REVERSE.

  5. Adjust the input rotation to 1950 ± 10 rpm.

  6. Record the values in Table 21.

  7. Verify test points with the values in Table 19.

    Note: Verify test points with values in Table 20 if the transmission has been updated per SMAG SEPD1916 or SMAG M0064316.

  8. Adjust the input rotation to 400 ± 10 rpm.

  9. Shift the transmission to NEUTRAL.

  10. Shift the transmission to FORWARD 1.

  11. Adjust the input rotation to 1950 ± 10 rpm.

  12. Record the values in Table 21.

  13. Verify test points with the values in Table 19.

    Note: Verify test points with values in Table 20 if the transmission has been updated per SMAG SEPD1916 or SMAG M0064316.

  14. Adjust the input rotation to 400 ± 10 rpm.

  15. Shift the transmission to the next gear. Repeat Steps 11 through 15 FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, and FORWARD 6. Do not test FORWARD 7.

  16. Adjust the input rotation to 400 ± 10 rpm.

  17. Shift the transmission through gear ranges FORWARD 5, FORWARD 4, FORWARD 3, FORWARD 2, FORWARD 1, and NEUTRAL.

Clutch Leakage

    Note: The control leakage was recorded in Table 21 during the high idle checks. The input speed, input flow for the transmission control, and transmission lubrication oil were established during the high idle checks. Refer to Special Instruction, "High Idle Checks" for further information.

  1. Calculate the clutch leakage. Subtract the control leakage that is listed in Table 22.

  2. Record the values in Table 23.

  3. Verify test points with the values in Table 22.

Lube Checks

    Note: The following steps are for the lube check for the front module.

  1. Adjust the input flow for the transmission control to 227 ± 2 L/min (60 ± 0.5 US gpm).

  2. Adjust the input flow for the transmission lubrication oil until the lubrication oil flow to the front module is 113 ± 1 L/min (30 ± 0.2 US gpm).

  3. Adjust the input rotation to 400 ± 10 rpm.

  4. Shift the transmission to FORWARD 1.

  5. Adjust the input rotation to 1300 ± 10 rpm.

  6. Record the values in Table 26.

  7. Verify test points with the values in Table 24.

    Note: Verify test points with values in Table 25 if the transmission has been updated per SMAG SEPD1916 or SMAG M0064316.

  8. Adjust the input rotation to 400 ± 10 rpm.

  9. Shift the transmission to FORWARD 4.

  10. Adjust the input rotation to 1300 ± 10 rpm.

  11. Record the values in Table 26.

  12. Verify test points with the values in Table 24.

    Note: Verify test points with values in Table 25 if the transmission has been updated per SMAG SEPD1916 or SMAG M0064316.

  13. Adjust the input rotation to 400 ± 10 rpm.

  14. Shift the transmission to FORWARD 7.

  15. Adjust the input rotation to 1300 ± 10 rpm.

  16. Record the values in Table 26.

  17. Verify test points with the values in Table 24.

    Note: Verify test points with values in Table 25 if the transmission has been updated per SMAG SEPD1916 or SMAG M0064316.

  18. Adjust the input rotation to 400 ± 10 rpm.

  19. Shift the transmission to NEUTRAL.

    Note: The following steps are for the lube check for the rear module.

  20. Adjust the input flow for the transmission control to 227 ± 2 L/min (60 ± 0.5 US gpm).

  21. Adjust the input flow for the transmission lubrication oil until the lubrication oil flow to the rear module is 303 ± 1 L/min (80 ± 0.2 US gpm).

  22. Adjust the input rotation to 400 ± 10 rpm.

  23. Shift the transmission to FORWARD 1.

  24. Adjust the input rotation to 1300 ± 10 rpm.

  25. Record the values in Table 26.

  26. Verify test points with the values in Table 24.

    Note: Verify test points with values in Table 25 if the transmission has been updated per SMAG SEPD1916 or SMAG M0064316.

  27. Adjust the input rotation to 400 ± 10 rpm.

  28. Shift the transmission to FORWARD 4.

  29. Adjust the input rotation to 1300 ± 10 rpm.

  30. Record the values in Table 26.

  31. Verify test points with the values in Table 24.

    Note: Verify test points with values in Table 25 if the transmission has been updated per SMAG SEPD1916 or SMAG M0064316.

  32. Adjust the input rotation to 400 ± 10 rpm.

  33. Shift the transmission to FORWARD 7.

  34. Adjust the input rotation to 1300 ± 10 rpm.

  35. Record the values in Table 26.

  36. Verify test points with the values in Table 24.

    Note: Verify test points with values in Table 25 if the transmission has been updated per SMAG SEPD1916 or SMAG M0064316.

  37. Adjust the input rotation to 400 ± 10 rpm.

  38. Shift the transmission to NEUTRAL.

Contamination Control

  1. Allow the oil to drain from the transmission.

  2. Take an oil sample of the test bench oil supply. Oil contamination must be a minimum *ISO 16/13.

  3. Record the results in Table 27.

  4. Remove the filters, magnets, and the screens.

  5. Clean the filters, magnets, and the screens.

Transmission Bench Test Data Sheet

Show/hide table
Table 6
CATERPILLAR  Transmission Bench Test Data Sheet  Test Date:_______ 
Model:_______
Work Order:_______  Serial No.:_______ 

Solenoid Test

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Table 7
Solenoid Test  Measured Resistance (Ω at 25 °C (77 °F)) 
Solenoid  1  2  3  4  5  6  7  8 
Description  Clutch 1  Clutch 2  Clutch 3  Clutch 4  Clutch 5  Clutch 6  Clutch 7  Latching 
Measured Resistance  8.4 to 9.6 Ω  8.4 to 9.6 Ω  8.4 to 9.6 Ω  8.4 to 9.6 Ω  8.4 to 9.6 Ω  8.4 to 9.6 Ω  8.4 to 9.6 Ω  31.7 to 34.1 Ω 

Show/hide table
Table 8
Solenoid Test  Measured Resistance (Ω at 25 °C (77 °F)) 
Solenoid  1  2  3  4  5  6  7  8 
Description  Clutch 1  Clutch 2  Clutch 3  Clutch 4  Clutch 5  Clutch 6  Clutch 7  Latching 
Measured Resistance  _______ Ω  _______ Ω  _______ Ω  _______ Ω  _______ Ω  _______ Ω  _______ Ω  _______ Ω 

Start Checks

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Table 9
Start Checks 
Test Point  Min  Max 
Transmission Control Supply Pressure  2186 kPa (317 psi)  2351 kPa (340 psi) 
Transmission Clutch Latching Pressure  1829 kPa (265 psi)  2137 kPa (310 psi) 
Pressure for the Transmission Lubrication Oil  74 kPa (11 psi)  103 kPa (15 psi) 
Lubrication Pressure (Front Module)  57 kPa (8 psi)  87 kPa (13 psi) 
Lubrication Pressure (Rear Module)  46 kPa (7 psi)  76 kPa (11 psi) 

Show/hide table
Table 10
Start Checks 
Test Point  Min  Max 
Transmission Control Supply Pressure  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Transmission Clutch Latching Pressure  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Pressure for the Transmission Lubrication Oil  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Lubrication Pressure (Front Module)  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Lubrication Pressure (Rear Module)  _______kPa
_______(psi) 		 _______kPa
_______(psi) 

Speed Sensor Test

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Table 11
Speed Sensor Test  Input Speed is 700 ± 10 rpm. 
Gear  N  R  F1  F2  F3  F4  F5  F6  F7 
Speed  0–50 rpm  84–184 rpm  67–167 rpm  108–208 rpm  163–263 rpm  237–337 rpm  337–437 rpm  474–574 rpm  651–751 rpm 

Show/hide table
Table 12
Speed Sensor Test  Input Speed is 700 ± 10 rpm. 
Gear  N  R  F1  F2  F3  F4  F5  F6  F7 
Speed 
_____rpm 
_____rpm 
_____rpm 
_____rpm 
_____rpm 
_____rpm 
_____rpm 
_____rpm 
_____rpm 

Latching Test (Zero Speed With Lockup)

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Table 13
Latching Test (Zero Speed With Lockup) 
Channel  Latched Condition  Unlatched Condition 
Transmission Control Supply Pressure  2415 ± 345 kPa (350 ± 50 psi)  2415 ± 345 kPa (350 ± 50 psi) 
Latching Pressure  0 ± 70 kPa (0± 10 psi)  2415 ± 345 kPa (350 ± 50 psi) 
Lockup Clutch Pressure  2415 ± 345 kPa (350 ± 50 psi)  2415 ± 345 kPa (350 ± 50 psi) 
Clutch Port 1  2415 ± 345 kPa (350 ± 50 psi)  1550 ± 170 kPa (225 ± 25 psi) 
Clutch Port 2  2415 ± 345 kPa (350 ± 50 psi)  1550 ± 170 kPa (225 ± 25 psi) 
Clutch Port 3  2415 ± 345 kPa (350 ± 50 psi)  1550 ± 170 kPa (225 ± 25 psi) 
Clutch Port 4  2415 ± 345 kPa (350 ± 50 psi)  1550 ± 170 kPa (225 ± 25 psi) 
Clutch Port 5  2415 ± 345 kPa (350 ± 50 psi)  1550 ± 170 kPa (225 ± 25 psi) 
Clutch Port 6  2415 ± 345 kPa (350 ± 50 psi)  1720 ± 170 kPa (250 ± 25 psi) 

Show/hide table
Table 14
Latching Test (Zero Speed With Lockup) 
Channel  Latched Condition  Unlatched Condition 
Transmission Control Supply Pressure  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Latching Pressure  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Lockup Clutch Pressure  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 1  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 2  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 3  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 4  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 5  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 6  _______kPa
_______(psi) 		 _______kPa
_______(psi) 

Latching Test (Front And Rear)

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Table 15
Latching Test (Front and Rear Modules) 
Channel  Latched Condition  Unlatched Condition 
Transmission Control Supply Pressure  2415 ± 345 kPa (350 ± 50 psi)  2415 ± 345 kPa (350 ± 50 psi) 
Transmission Clutch Latching Pressure  0 ± 70 kPa (0± 10 psi)  2415 ± 345 kPa (350 ± 50 psi) 
Lockup Clutch Pressure  2415 ± 345 kPa (350 ± 50 psi)  2415 ± 345 kPa (350 ± 50 psi) 
Clutch Port 1  2415 ± 345 kPa (350 ± 50 psi)  1550 ± 170 kPa (225 ± 25 psi) 
Clutch Port 2  2415 ± 345 kPa (350 ± 50 psi)  1550 ± 170 kPa (225 ± 25 psi) 
Clutch Port 3  2415 ± 345 kPa (350 ± 50 psi)  1550 ± 170 kPa (225 ± 25 psi) 
Clutch Port 4  2415 ± 345 kPa (350 ± 50 psi)  1550 ± 170 kPa (225 ± 25 psi) 
Clutch Port 5  2415 ± 345 kPa (350 ± 50 psi)  1551 ± 170 kPa (225 ± 25 psi) 
Clutch Port 6  2415 ± 345 kPa (350 ± 50 psi)  1720 ± 170 kPa (250 ± 25 psi) 

Show/hide table
Table 16
Latching Test (Front Module) 
Channel  Latched Condition  Unlatched Condition 
Transmission Control Supply Pressure  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Transmission Clutch Latching Pressure  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Lockup Clutch Pressure  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 1  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 2  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 3  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 4  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 5  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 6  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Latching Test (Rear Module) 
Channel  Latched Condition  Unlatched Condition 
Transmission Control Supply Pressure  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Transmission Clutch Latching Pressure  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Lockup Clutch Pressure  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 1  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 2  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 3  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 4  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 5  _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Clutch Port 6  _______kPa
_______(psi) 		 _______kPa
_______(psi) 

Medium and High Idle Checks

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Table 17
Medium Idle Checks 
Gear  Test Point  1300 rpm 
Min Max
All  Transmission Control Supply Pressure
"P1" 		 2380 kPa (345 psi)  2540 kPa (368 psi) 
Transmission Control Supply Pressure Minus Latching Pressure (1)
"P1 − P6" 		34 kPa (5 psi)  310 kPa (45 psi) 
Transmission Control Return Pressure(2)
"P10" 		320 kPa (46 psi)  390 kPa (56 psi) 
Transmission Clutch Latching Pressure (1)
"P6" 		1974 kPa (286 psi)  2282 kPa (330 psi) 
Latching Pressure Sensor (3) 63 Percent Duty Cycle  69 Percent Duty Cycle 
Transmission Oil Pressure Sensor (3) 27 Percent Duty Cycle  35 Percent Duty Cycle 
Transmission Oil Temperature (4) 47 °C (117 °F)  55 °C (131 °F) 
Transmission Oil Temperature Sensor (3) 43 Percent Duty Cycle  50 Percent Duty Cycle 
Lockup Supply Flow(5)
"F5" 		12 L/min (3.2 US gpm)  14 L/min (3.7 US gpm) 
Lockup Supply Pressure
"P15" 		2310 kPa (335 psi)  2450 kPa (355 psi) 
Lubrication Flow (Front Module)
"F1"(6) 		83 L/min (22 US gpm)  98 L/min (26 US gpm) 
Lubrication Flow (Rear Module)
"F2 − F1"(6) 		356 L/min (94 US gpm)  488 L/min (129 US gpm) 
Transmission Lubrication Oil (Supply)
"P2"(6) 		248 kPa (36 psi)  324 kPa (47 psi) 
Lubrication Pressure (Front Module)
"P5"(6) 		193 kPa (28 psi)  269 kPa (39 psi) 
Lubrication Pressure (Rear Module)
"P3"(6) 		145 kPa (21 psi)  220 kPa (32 psi) 
N  Control Leakage  47.7 L/min (12.6 US gpm)  55 L/min (14.5 US gpm) 
Input Power   92.3 kW (123.8 hp) 
R  Control Leakage  49 L/min (12.9 US gpm)  56.3 L/min (14.9 US gpm) 
Input Power   92.5 kW (124 hp) 
F1  Control Leakage  48 L/min (12.7 US gpm)  55.1 L/min (14.6 US gpm) 
Input Power   53.8 kW (72.1 hp) 
F2  Control Leakage  48.4 L/min (12.8 US gpm)  55.7 L/min (14.7 US gpm) 
Input Power   63.5 kW (85.1 hp) 
F3  Control Leakage  54.1 L/min (14.3 US gpm)  61.1 L/min (16.1 US gpm) 
Input Power   89.4 kW (119.9 hp) 
F4  Control Leakage  48.7 L/min (12.9 US gpm)  55.7 L/min (14.7 US gpm) 
Input Power   55 kW (73.8 hp) 
F5  Control Leakage  54.3 L/min (14.3 US gpm)  61.1 L/min (16.1 US gpm) 
Input Power   82.9 kW (111.1 hp) 
F6  Control Leakage  54.6 L/min (14.4 US gpm)  62.3 L/min (16.5 US gpm) 
Input Power   97.4 kW (130.6 hp) 
F7  Control Leakage  59.8 L/min (15.8 US gpm)  68.2 L/min (18 US gpm) 
Input Power   182.6 kW (244.8 hp) 
Show/hide table
(1) Latching pressure is measured at the pressure tap.
(2) Adjust the ball valve at the auxiliary tank.
(3) Measured at Tooling (T)
(4) Measured at Tooling (G)
(5) Adjust the ball valve at Tooling (M).
(6) Use values in Table 18 if the transmission has been updated per SMAG SEPD1916 or SMAG M0064316.

Show/hide table
Table 18
Medium Idle Checks for Updated Models 
Gear  Test Point  1300 rpm 
Min Max
All  Lubrication Flow (Front Module)
"F1" 		 109 L/min (29 US gpm)  133 L/min (35 US gpm) 
Lubrication Flow (Rear Module)
"F2 − F1" 		325 L/min (86 US gpm)  349 L/min (92 US gpm) 
Transmission Lubrication Oil (Supply)
"P2" 		261 kPa (38 psi)  331 kPa (48 psi) 
Lubrication Pressure (Front Module)
"P5" 		172 kPa (25 psi)  262 kPa (38 psi) 
Lubrication Pressure (Rear Module)
"P3" 		0 kPa (0 psi)  55 kPa (8 psi) 

Show/hide table
Table 19
High Idle Checks 
Gear  Test Point  1950 rpm 
Min Max
All  Transmission Control Supply Pressure
"P1" 		 2500 kPa (363 psi)  2670 kPa (387 psi) 
Transmission Control Supply Pressure Minus Latching Pressure (1)
"P1 − P6" 		34 kPa (5 psi)  310 kPa (45 psi) 
Transmission Control Return Pressure(2)
"P10" 		790 kPa (115 psi)  900 kPa (131 psi) 
Transmission Clutch Latching Pressure (1)
"P6" 		2065 kPa (300 psi)  2374 kPa (344 psi) 
Latching Pressure Sensor (3) 63 Percent Duty Cycle  72 Percent Duty Cycle 
Transmission Oil Pressure Sensor (3) 53 Percent Duty Cycle  70 Percent Duty Cycle 
Transmission Oil Temperature (4) 47 °C (117 °F)  55 °C (131 °F) 
Transmission Oil Temperature Sensor (3) 43 Percent Duty Cycle  50 Percent Duty Cycle 
Lockup Supply Flow(5)
"F5" 		12 L/min (3.30 US gpm)  14 L/min (3.72 US gpm) 
Lockup Supply Pressure
"P15" 		2410 kPa (350 psi)  2560 kPa (371 psi) 
Lubrication Flow (Front Module)
"F1"(6) 		114 L/min (30 US gpm)  136 L/min (36 US gpm) 
Lubrication Flow (Rear Module)
"F2 − F1"(6) 		469 L/min (124 US gpm)  492 L/min (130 US gpm) 
Transmission Lubrication Oil (Supply)
"P2"(6) 		448 kPa (65 psi)  579 kPa (84 psi) 
Lubrication Pressure (Front Module)
"P5"(6) 		359 kPa (52 psi)  490 kPa (71) 
Lubrication Pressure (Rear Module)
"P3"(6) 		276 kPa (40 psi)  400 kPa (58 psi) 
N  Control Leakage  60.9 L/min (16.10 US gpm)  70.9 L/min (18.70 US gpm) 
Input Power   113.4 kW (152 hp) 
R  Control Leakage  62.4 L/min (16.50 US gpm)  72.4 L/min (19.10 US gpm) 
Input Power   242.7 kW (325.4 hp) 
F1  Control Leakage  61.3 L/min (16.20 US gpm)  71.4 L/min (18.90 US gpm) 
Input Power   119.3 kW (159.9 hp) 
F2  Control Leakage  61.6 L/min (16.30 US gpm)  71.7 L/min (19.00 US gpm) 
Input Power   125.6 kW (168.4 hp) 
F3  Control Leakage  67.2 L/min (17.80 US gpm)  77 L/min (20.40 US gpm) 
Input Power   197.4 kW (264.7 hp) 
F4  Control Leakage  62 L/min (16.40 US gpm)  71.7 L/min (19.00 US gpm) 
Input Power   106.5 kW (142.8 hp) 
F5  Control Leakage  67.7 L/min (17.90 US gpm)  76.9 L/min (20.30 US gpm) 
Input Power   185.6 kW (248.8 hp) 
F6  Control Leakage  68 L/min (18.00 US gpm)  78.1 L/min (20.60 US gpm) 
Input Power   209.4 kW (280.8 hp) 
Show/hide table
(1) Latching pressure is measured at the pressure tap.
(2) Adjust the ball valve at the auxiliary tank.
(3) Measured at Tooling (T)
(4) Measured at Tooling (G)
(5) Adjust the ball valve at Tooling (M).
(6) Use values in Table 20 if the transmission has been updated per SMAG SEPD1916 or SMAG M0064316.

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Table 20
High Idle Checks for Updated Models 
Gear  Test Point  1300 rpm 
Min Max
All  Lubrication Flow (Front Module)
"F1" 		 151 L/min (40 US gpm)  179 L/min (47 US gpm) 
Lubrication Flow (Rear Module)
"F2 − F1" 		453 L/min (120 US gpm)  481 L/min (127 US gpm) 
Transmission Lubrication Oil (Supply)
"P2" 		537 kPa (78 psi)  621 kPa (90 psi) 
Lubrication Pressure (Front Module)
"P5" 		339 kPa (49 psi)  483 kPa (70 psi) 
Lubrication Pressure (Rear Module)
"P3" 		0 kPa (0 psi3)  69 kPa (10 psi) 

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Table 21
Medium and High Idle Checks 
Gear  Test Point  1300 rpm  1950 rpm 
All Gears  Transmission Control Supply Pressure
"P1" 		 _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Transmission Control Supply Pressure Minus Latching Pressure (1)
"P1 − P6" 		_______kPa
_______(psi) 		 _______kPa
_______(psi) 
Transmission Control Return Pressure(2)
"P10" 		_______kPa
_______(psi) 		 _______kPa
_______(psi) 
Transmission Clutch Latching Pressure (1)
"P6" 		_______kPa
_______(psi) 		 _______kPa
_______(psi) 

Latching Pressure Sensor (3) 		Percent Duty Cycle  Percent Duty Cycle 

Transmission Oil Pressure Sensor (3) 		Percent Duty Cycle  Percent Duty Cycle 

Transmission Oil Temperature (4) 		_______°C
_______(°F) 		 _______°C
_______(°F) 
Transmission Oil Temperature Sensor (3) Percent Duty Cycle  Percent Duty Cycle 
Lockup Supply Flow(5)
"F5" 		_______L/min
_______(gpm) 		 _______L/min
_______(gpm) 
Lockup Supply Pressure
"P15" 		_______kPa
_______(psi) 		 _______kPa
_______(psi) 
Lubrication Flow (Front Module)
"F1" 		_______L/min
_______(gpm) 		 _______L/min
_______(gpm) 
Lubrication Flow (Rear Module)
"F2 − F1" 		_______L/min
_______(gpm) 		 _______L/min
_______(gpm) 
Transmission Lubrication Oil (Supply)
"P2" 		_______kPa
_______(psi) 		 _______kPa
_______(psi) 
Lubrication Pressure (Front Module)
"P5" 		_______kPa
_______(psi) 		 _______kPa
_______(psi) 
Lubrication Pressure (Rear Module)
"P3" 		_______kPa
_______(psi) 		 _______kPa
_______(psi) 
N  Control Leakage  _______L/min
_______(gpm) 		 _______L/min
_______(gpm) 
Input Power _______kW
_______(hp) 		 _______kW
_______(hp) 
R  Control Leakage  _______L/min
_______(gpm) 		 _______L/min
_______(gpm) 
Input Power kW (hp)  kW (hp) 
F1  Control Leakage  _______L/min
_______(gpm) 		 _______L/min
_______(gpm) 
Input Power _______kW
_______(hp) 		 _______kW
_______(hp) 
F2  Control Leakage  _______L/min
_______(gpm) 		 _______L/min
_______(gpm) 
Input Power _______kW
_______(hp) 		 _______kW
_______(hp) 
F3  Control Leakage  _______L/min
_______(gpm) 		 _______L/min
_______(gpm) 
Input Power _______kW
_______(hp) 		 _______kW
_______(hp) 
F4  Control Leakage  _______L/min
_______(gpm) 		 _______L/min
_______(gpm) 
Input Power _______kW
_______(hp) 		 _______kW
_______(hp) 
F5  Control Leakage  _______L/min
_______(gpm) 		 _______L/min
_______(gpm) 
Input Power _______kW
_______(hp) 		 _______kW
_______(hp) 
F6  Control Leakage  _______L/min
_______(gpm) 		 _______L/min
_______(gpm) 
Input Power _______kW
_______(hp) 		 _______kW
_______(hp) 
F7  Control Leakage  _______L/min
_______(gpm) 		  
Input Power _______kW
_______(hp) 		  
Show/hide table
(1) Latching pressure is measured at the pressure tap.
(2) Adjust the ball valve at the auxiliary tank.
(3) Measured at Tooling (T)
(4) Measured at Tooling (G)
(5) Adjust the ball valve at Tooling (M).

Clutch Leakage Checks

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Table 22
Clutch Leakage Checks 
Clutch  Control Leakage  Maximum 
CL 1  F3 − F1(1)  7.7 L/min (2 US gpm) 
F3 − F2 7.3 L/min (1.9 US gpm) 
F5 − F4 7.3 L/min (1.9 US gpm) 
CL 2  F2 − F1  1.5 L/min (0.4 US gpm) 
F2 − F3 −3.5 L/min (−0.9 US gpm) 
F4 − F5 −3.8 L/min (−1 US gpm) 
CL 3  F1 − F2  0.8 L/min (0.2 US gpm) 
F1 − F3 −3.9 L/min (−1 US gpm) 
CL 4  F6 − F2  8.3 L/min (2.2 US gpm) 
F6 − F4 8.4 L/min (2.2 US gpm) 
F6 − R 9.1 L/min (2.4 US gpm) 
CL 5  F4 − F2  1.2 L/min (0.3 US gpm) 
F4 − F6 −4.2 L/min (−1.1 US gpm) 
F4 − R 2 L/min (0.5 US gpm) 
F5 − F3 1.3 L/min (0.3 US gpm) 
CL 6  F2 − F4  1.1 L/min (0.3 US gpm) 
F2 − F6 −4.3 L/min (−1.1 US gpm) 
F2 − R 1.9 L/min (0.5 US gpm) 
F3 − F5 1 L/min (0.3 US gpm) 
CL 7  R − F2  0.3 L/min (0.1 US gpm) 
R − F4 0.3 L/min (0.1 US gpm) 
R − F6 −5.2 L/min (−1.4 US gpm) 
Show/hide table
(1) Example: F3 (CL1 and CL 6) minus F1 (CL3 and CL6)Refer to the Table 5 (Clutch Engagement Table) to find the correct clutch assignments for each gear.

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Table 23
Clutch Leakage Checks 
Clutch  Gear Range  Minus  Gear Range  Equal  Difference 
CL 1  F3  −  F1  =   
F3 −  F2  =   
F5 −  F4  =   
CL 2  F2  −  F1  =   
F2 −  F3  =   
F4 −  F5  =   
CL 3  F1  −  F2  =   
F1 −  F3  =   
CL 4  F6  −  F2  =   
F6 −  F4  =   
F6 −  R  =   
CL 5  F4  −  F2  =   
F4 −  F6  =   
F4 −  R  =   
F5 −  F3  =   
CL 6  F2  −  F4  =   
F2 −  F6  =   
F2 −  R  =   
F3 −  F5  =   
CL 7  R  −  F2  =   
R −  F4  =   
R −  F6  =   

Lube Checks

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Table 24
Front Lube Check 
Test Point  F1  F4  F7 
Min Max  Min  Max  Min  Max 
Transmission Oil Temperature  49 °C (120 °F)  54 °C (130 °F)  49 °C (120 °F)  54 °C (130 °F)  49 °C (120 °F)  54 °C (130 °F) 
Transmission Control Supply Pressure  2400 kPa (350 psi)  2540 kPa (370 psi)  2400 kPa (350 psi)  2540 kPa (370 psi)  2380 kPa (345 psi)  2520 kPa (365 psi) 
Transmission Control Return Flow  158 L/min (41.6 US gpm)  173 L/min (45.7 US gpm)  158 L/min (41.6 US gpm)  172 L/min (45.5 US gpm)  144 L/min (37.9 US gpm)  161 L/min (42.5 US gpm) 
Lockup Supply Flow  11.6 L/min (3.1 US gpm)  14.6 L/min (3.9 US gpm)  11.6 L/min (3.1 US gpm)  14.6 L/min (3.9 US gpm)  11.5 L/min (3 US gpm)  14.5 L/min (3.8 US gpm) 
Lockup Supply Pressure  2320 kPa (337 psi)  2460 kPa (357 psi)  2320 kPa (337 psi)  2460 kPa (357 psi)  2300 kPa (334 psi)  2440 kPa (354 psi) 
Lubrication Pressure (Front Module)(1)  283 kPa (41 psi)  365 kPa (53 psi)  283 kPa (41 psi)  365 kPa (53 psi)  303 kPa (44 psi)  386 kPa (56 psi) 
Lubrication Pressure (Rear Module)(1)  214 kPa (31 psi)  296 kPa (43 psi)  214 kPa (31 psi)  296 kPa (43 psi)  228 kPa (33 psi)  310 kPa (45 psi) 
Rear Lube Check 
Test Point  F1  F4  F7 
Min Max  Min  Max  Min  Max 
Transmission Oil Temperature  49 °C (120 °F)  54 °C (130 °F)  49 °C (120 °F)  54 °C (130 °F)  49 °C (120 °F)  54 °C (130 °F) 
Transmission Control Supply Pressure  2400 kPa (350 psi)  2540 kPa (370 psi)  2400 kPa (350 psi)  2540 kPa (370 psi)  2380 kPa (345 psi)  2520 kPa (365 psi) 
Transmission Control Return Flow  159 L/min (41.9 US gpm)  168 L/min (44.4 US gpm)  155 L/min (41 US gpm)  170 L/min (45 US gpm)  143 L/min (37.8 US gpm)  156 L/min (41.2 US gpm) 
Lockup Supply Flow  11.6 L/min (3.1 US gpm)  14.6 L/min (3.9 US gpm)  11.6 L/min (3.1 US gpm)  14.6 L/min (3.9 US gpm)  11.5 L/min (3 US gpm)  14.5 L/min (3.8 US gpm) 
Lockup Supply Pressure  2320 kPa (337 psi)  2460 kPa (357 psi)  2320 kPa (337 psi)  2460 kPa (357 psi)  2300 kPa (333 psi)  2440 kPa (353 psi) 
Lubrication Pressure (Front Module)  145 kPa (21 psi)  179 kPa (26 psi)  145 kPa (21 psi)  179 kPa (26 psi)  145 kPa (21 psi)  193 kPa (28 psi) 
Lubrication Pressure (Rear Module)(1)  103 kPa (15 psi)  145 kPa (21 psi)  103 kPa (15 psi)  145 kPa (21 psi)  110 kPa (16 psi)  152 kPa (22 psi) 
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(1) Use values in Table 25 if the transmission has been updated per SMAG SEPD1916 or SMAG M0064316.

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Table 25
Front Lube Check 
Test Point  F1  F4  F7 
Min Max  Min  Max  Min  Max 
Lubrication Pressure (Front Module)  172 kPa (25 psi)  241 kPa (35 psi)  172 kPa (25 psi)  241 kPa (35 psi)  172 kPa (25 psi)  241 kPa (35 psi) 
Lubrication Pressure (Rear Module)  0 kPa (0 psi)  69 kPa (10 psi)  0 kPa (0 psi)  69 kPa (10 psi)  0 kPa (0 psi)  69 kPa (10 psi) 
Rear Lube Check 
Test Point  F1  F4  F7 
Min Max  Min  Max  Min  Max 
Lubrication Pressure (Rear Module)  0 kPa (0 psi)  69 kPa (10 psi)  0 kPa (0 psi)  69 kPa (10 psi)  0 kPa (0 psi)  69 kPa (10 psi) 

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Table 26
Front Lube Check 
Test Point  F1  F4  F7 

Transmission Oil Temperature 		 _______°C
_______°F 		 _______°C
_______°F 		 _______°C
_______°F 
Transmission Control Supply Pressure  _______kPa
_______(psi) 		 _______kPa
_______(psi) 		 _______kPa
_______(psi) 

Transmission Control Return Flow 		 _______L/min
_______(gpm) 		 _______L/min
_______(gpm) 		 _______L/min
_______(gpm) 

Lockup Supply Flow 		 _______L/min
_______(gpm) 		 _______L/min
_______(gpm) 		 _______L/min
_______(gpm) 

Lockup Supply Pressure 		 _______kPa
_______(psi) 		 _______kPa
_______(psi) 		 _______kPa
_______(psi) 

Lubrication Pressure (Front Module) 		 _______kPa
_______(psi) 		 _______kPa
_______(psi) 		 _______kPa
_______(psi) 

Lubrication Pressure (Rear Module) 		 _______kPa
_______(psi) 		 _______kPa
_______(psi) 		 _______kPa
_______(psi) 
Rear Lube Check 
Test Point  F1  F4  F7 

Transmission Oil Temperature 		 _______°C
_______°F 		 _______°C
_______°F 		 _______°C
_______°F 
Transmission Control Supply Pressure  _______kPa
_______(psi) 		 _______kPa
_______(psi) 		 _______kPa
_______(psi) 

Transmission Control Return Flow 		 _______L/min
_______(gpm) 		 _______L/min
_______(gpm) 		 _______L/min
_______(gpm) 

Lockup Supply Flow 		 _______L/min
_______(gpm) 		 _______L/min
_______(gpm) 		 _______L/min
_______(gpm) 

Lockup Supply Pressure 		 _______kPa
_______(psi) 		 _______kPa
_______(psi) 		 _______kPa
_______(psi) 

Lubrication Pressure (Front Module) 		 _______kPa
_______(psi) 		 _______kPa
_______(psi) 		 _______kPa
_______(psi) 

Lubrication Pressure (Rear Module) 		 _______kPa
_______(psi) 		 _______kPa
_______(psi) 		 _______kPa
_______(psi) 

Contamination Control

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Table 27
ISO Particle Count  Sample the test bench oil supply.
*ISO 4406 is 16/13 or better 		 ________/________Particle Count 

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Table 28






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