Bench Test Procedure For A 735 Articulated Truck Transmission {3030, 3073, 3139} Caterpillar


Bench Test Procedure For A 735 Articulated Truck Transmission {3030, 3073, 3139}

Usage:

735 AWR
Articulated Truck
735 (S/N: B1N1-UP; AWR1-UP)

Introduction

Table 1
Revision  Summary of Changes in REHS1409 
07  Added Arrangement Number
Added Serial Number Prefix B1N 
06  Standardized. 
05  Updated Introduction.
Added "Think Safety' graphic.
Updated Table 5. 
04  Updated introduction and added Canceled Part Numbers section. 

© 2015 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 a specific transmission arrangement. Refer to Table 2 for the correct arrangements. Bench testing the transmission ensures correct assembly and operation of the component. Rotating a transmission provides the most conclusive evaluation. Testing allows the dealer to ensure that the transmission will operate properly in the machine. The specifications in this guideline are specific to bench testing the component. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This guideline must be used with the latest technical information that is available from Caterpillar.

For questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. to address an urgent need, 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 
735  153-6989, 227-8964, 233-7680 

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 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.



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 "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Collecting the Test Data

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

Data from each transmission arrangement is collected and stored. Averages from each transmission arrangement are used to compare values on portions of this transmission test. Always compare data that is collected from the same transmission arrangement that is being tested. Averages for the last 20 transmission arrangements should be maintained.

------ 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.


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

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.


------ 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: 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. For additional information about tooling, consult Caterpillar Service Tools Division.

Table 3
Required Tools 
Tool  Part Number  Part Description  Qty 
1U-9584  Rail As 
217-9718 Support 
1D-4586 Bolt (5/8-11X3.50 inch)  10 
4B-4281 Washer 
4K-0367 Full Nut  10 
8T-0348 Bolt (M16X2.0X50 mm) 
3B-4510 Lockwasher 
6V-9167 Bolt (M20X2.5X140 mm) 
8T-3282 Hard Washer 
439-3939 Link Bracket As 
4C-9998 Bracket As (TEST) 
217-9717  Drive Adapter 
6V-8200 Bolt (M12X1.25X35 mm) 
4C-4701  Spindle Adapter 
2J-5245 Bolt (3/8-16X1.75 inch) 
3B-4506 Lockwasher 
1U-5999  Spindle Gp 
8B-7997 Bolt (1/2-13X2.00 inch) 
3B-4506 Lockwasher 
1U-6721  Adapter As 
1U-9131  Drive Adapter (KEY) 
1U-9359  Drive Adapter 
1U-9722  Load Binder As (RATCHET TYPE) 
439-3940 Link Bracket As 
8T-4139 Bolt (M12X1.75X30 mm) 
8T-4223 Hard Washer 
1D-4719 Full Nut 
217-9719  Suction Adapter Gp 
6V-4248 Bolt (M10X1.50X25 mm) 
6V-5839 Washer 
1U-8301  Fitting 
9U-7445 Adapter 
1P-4578 Half Flange 
8C-9024 Fitting As (PLAIN) 
6V-3822 Bolt (M10X1.50X35 mm) 
6V-5839 Washer 
6V-3965 Fitting As (TEST) 
3J-1907 O-Ring Seal 
9U-7500  Transmission Analyzer Tool Gp 
OR
277-2362 Transmission Analyzer III Gp 
306-0397 Extension Cable 
9U-7496 Cable (TEST) 
1U-9480 Cable Adapter 
8T-0855  Pressure Gauge (0 to 4,000 kPa (0 to 580 psi)) 
8T-0854 Pressure Gauge (0 to 1,000 kPa (0 to 145 psi)) 
8T-0862 Pressure Gauge (-100 to 500 kPa (-15 to 72 psi)) 
8T-0863 Pressure Gauge (0 to 250 kPa (0 to 36 psi)) 
6V-4144 Coupler  13 
9U-7400  Multitach II Group 
155-2270  Connecting Plug Kit 
186-3736 Connector Socket 
5P-5677 Electrical Wire (18 AWG) 
Plug Assembly (Double Banana)(1) 
146-4080 Digital Multimeter 
(1) Pomona Model 1330-0

Installation Procedure



    Illustration 3g06000480

    Note: You will need to add two additional bolt holes on each side of the lower brackets. The holes will be drilled on the input end.

  1. Assemble Tooling (A).


    Illustration 4g00915751

  2. Install Tooling (A) to the output end of the transmission.


    Illustration 5g00915752

  3. Use a hoist to install the transmission on the test bench. The weight of the transmission is 950 kg (2094 lb).


    Illustration 6g00915754

  4. Install Tooling (A) to the input end of the transmission.


    Illustration 7g00915755

  5. Install Tooling (A) to the output end of the transmission.


    Illustration 8g00915756

  6. If necessary, remove the flex plate from the torque converter.

  7. Install Tooling (B) to the torque converter.


    Illustration 9g00915758

  8. Install Tooling (C) to the transmission case.


    Illustration 10g00915760

    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.

  9. Install Tooling (D) on Tooling (C).


    Illustration 11g00915764

  10. Tighten the collet on Tooling (D) to connect Tooling (D) to Tooling (B).


    Illustration 12g00915766

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


    Illustration 13g00915768

  12. 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).



    Illustration 14g00915772

  13. Align the transmission with the input drive shaft.

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


    Illustration 15g00915774

  15. Install the drive shaft guard.


    Illustration 16g03802221

  16. Tighten all four castle nuts and jack bolts.


    Illustration 17g00878734
    Input end of transmission

  17. Install Tooling (H) to the input end of the transmission.


    Illustration 18g00915777
    Output end of transmission

  18. Install Tooling (H) to the output end of the transmission.


    Illustration 19g06000482

  19. Remove the plate from the oil pan.

  20. Install Tooling (P) on the oil sump.

    Note: The rubber hose will fit over the sump. The brackets will secure the tooling.



    Illustration 20g00915783

  21. Install Tooling (J).


    Illustration 21g00915787

  22. Connect hose assembly (1) from the pump supply to Tooling (P).


    Illustration 22g00915790

  23. Connect hose assembly (2) from Tooling (J) to the No 2 flow meter inlet.

    Note: The No. 2 flow meter will measure the oil cooler flow.



    Illustration 23g00915791

  24. Connect hose assembly (3) from the No. 2 flow meter outlet to Tooling (J).


    Illustration 24g00915793

  25. Connect lube line (4) from the test bench to Tooling (D). Maintain an oil pressure of 275 kPa (40 psi).


    Illustration 25g00915797
    Cable connector (1-A) for No. 1 clutch solenoid (5)
    Cable connector (2-B) for No. 2 clutch solenoid (6)
    Cable connector (3-C) for No. 3 clutch solenoid (7)
    Cable connector (4-D) for No. 4 clutch solenoid (8)
    Cable connector (5-E) for No. 5 clutch solenoid (9)
    Cable connector (6-F) for No. 6 clutch solenoid (10)

  26. Connect Tooling (K) to six clutch solenoids.


    Illustration 26g00878743
    Cable connector (7-G) for lockup clutch solenoid (11)

  27. Connect Tooling (K) to lockup clutch solenoid (11).


    Illustration 27g00878744
    Cable connector (8-H) for latching solenoid (12)

    Note: Perform this step if your transmission arrangement is equipped with a latching system.

  28. Connect Tooling (K) to latching solenoid (12).


    Illustration 28g00878745
    Tooling (K)

  29. Connect Tooling (K) to a suitable location.


    Illustration 29g00878746
    (13) Transmission Hydraulic Control Relief Valve
    (14) Torque Converter Inlet Pressure

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

  30. Connect a pressure gauge to pressure tap (13).

  31. Connect a pressure gauge to pressure tap (14).


    Illustration 30g00915811
    (15) No. 1 Clutch Pressure
    (16) No. 2 Clutch Pressure
    (17) No. 3 Clutch Pressure
    (18) No. 4 Clutch Pressure
    (19) No. 5 Clutch Pressure
    (20) No. 6 Clutch Pressure

  32. Connect six pressure gauges to pressure taps (15), (16), (17), (18), (19), and (20).


    Illustration 31g00915824
    (21) Lockup Clutch Pressure

  33. Connect a pressure gauge to pressure tap (21).


    Illustration 32g00915825
    (22) Latching Rail Pressure

  34. Connect a pressure gauge to pressure tap (22).


    Illustration 33g00915828
    (23) Torque Converter Outlet Pressure

  35. Connect a pressure gauge to pressure tap (23).


    Illustration 34g00915831
    (24) Lubrication Pressure

  36. Connect a pressure gauge to pressure tap (24).


    Illustration 35g00915833
    Tooling (M)


    Illustration 36g06003033
    Tooling (M)

  37. Install Tooling (M) on the output yoke.


    Illustration 37g00877510
    Tooling (K)


    Illustration 38g01457869
    Tooling (K)

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

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

Test Procedure

TA2 Navigation

The 735 transmission must be shifted sequentially through the gear ranges.

The 9U-7500 Transmission Analyzer Tool Gp 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.



Illustration 39g00878491

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

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

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 harness failure.

Use the "2" key to turn off the lockup solenoid, and use the "2" key to turn on the solenoid.

Note: This function is only available in NEUTRAL, FORWARD 1, and FORWARD 2.



Illustration 40g00878493

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



Illustration 41g00878495

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



Illustration 42g00915664

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

TA3 Navigation

  1. Select “Articulated Trucks”.

  2. Select “735-24V”.

Harness Test (TA3 only)

  1. Make sure that the harness is properly connected.

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

  3. Record the values in Table 8.

    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.


    Illustration 43g02720621

    Note: The transmission must be in the NEUTRAL position.

  2. Rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 800 ± 30 rpm. Hold until the lubrication pressure rises to 14 kPa (2 psi).

    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.

  3. The lubrication pressure must be 41 ± 28 kPa (6 ± 4 psi).

    Note: If there is no lube pressure after 3 seconds, stop input rotation and check connections on test bench and transmission.

  4. Record the value in Table 9.

  5. Shift the transmission through all gear ranges to eliminate air from the transmission controls.

  6. Verify that the active clutches are correct for each gear range. Refer to Table 4.

  7. Verify that the output speeds match the values in Table 4.

Table 4
Clutch Engagement Check 
Gear  Clutches  Output Speed(1)  Output Speed (2) 
1 2  3  4  5  6  L
U
C
 
          X       
    X      X    179  426 
F1        X    X  X  140  332 
F2  X          X  X  224  532 
F3  X      X      X  294  699 
F4  X        X    X  411  975 
F5  X    X        X  560  1330 
F6  X  X          X  800  1900 
F7    X  X        X  1088  2584 
F8    X      X    X  1268  3010 
(1) The input speed is 700 rpm and the lockup clutch is engaged.
(2) The input speed is 1900 rpm and the lockup clutch is engaged.

Low Idle Checks

    Note: Make all shifts from NEUTRAL at 800 ± 25 rpm.

  1. Adjust the input rotation to 800 ± 25 rpm in the NEUTRAL position.

  2. Shift the transmission through each gear range.

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

  3. Record the values in Table 11 and 13.

  4. Verify all test points with the values in Table 10 and Table 12.

High Idle Checks and Parasitic Loss Test

    Note: Make all shifts from NEUTRAL at 800 ± 25 rpm.

  1. Adjust the input rotation to 800 ± 25 rpm in the NEUTRAL position.

  2. Shift the transmission to REVERSE.

  3. Adjust the input rotation to 1900 ± 25 rpm.

  4. Record the values in Table 15 and Table 17.

  5. Verify that the power loss does not exceed the value in Table 14.

  6. Verify all test points with the values in Table 14 and Table 16.

  7. Adjust the input rotation to 800 ± 25 rpm.

  8. Shift the transmission to NEUTRAL.

  9. Shift the transmission to FORWARD 1.

  10. Adjust the input rotation to 1900 ± 25 rpm.

  11. Record the values in Table 15 and Table 17.

  12. Verify that the power loss does not exceed the value in Table 14.

  13. Verify all test points with the values in Table 14 and Table 16.

  14. Adjust the input rotation to 800 ± 25 rpm.

  15. Shift the transmission through the remaining forward ranges. Repeat Steps 10 through 14 for each gear range.

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

Pump Flow Check

  1. Adjust the input rotation to 800 ± 25 rpm in NEUTRAL.

  2. Shift the transmission to FORWARD 2.

  3. Increase the input rotation until the cooler flow is equal to 95 ± 31 L/min (25 ± 8 US gpm).

  4. The lubrication pressure must be 159 ± 28 kPa (23 ± 4 psi).

  5. The input rotation must be between 1950 ± 100 rpm.

  6. Record the values in Table 18.

  7. Adjust the input rotation to 800 ± 25 rpm.

  8. Shift the transmission through FORWARD 1 to the NEUTRAL position.

Latching Test

    Note: Perform this test if your transmission arrangement is equipped with a latching system.

  1. Adjust the input rotation to 800 ± 25 rpm in NEUTRAL.

  2. Shift the transmission to FORWARD 1.

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

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

    Note: The clutch pressure must recover to the top pressure within 2 seconds. Top pressure is the pressure that was present before the de-energized state. The pressure must remain at least 0.3 seconds to pass the latching test.

  5. Press the "8" key to return the harness to normal operation.

    Note: Make sure that the pressure in the latching rail returns to the system pressure.

  6. Shift the transmission to the next gear range.

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

  8. Repeat Steps 3 through 7 until all forward gear ranges are tested and recorded.

Table 5
Transmission Clutch Assignments 
Operation  Normal Operation 
Harness Fault
1 2  3  4  5  6 
F1        X    X 
    X    X 
F2  X          X 
X         X 
F3  X      X     
X     X     
F4  X        X   
X       X   
F5      X       
  X       
F6    X         
X         
F7    X  X       
X  X       
F8    X      X   
X      X   

Speed Sensor Test

    Note: This transmission arrangement has four speed sensors that must be tested. There is one engine output speed sensor, one torque converter output speed sensor, and two transmission output speed sensors. Identify each speed sensor.

  1. Stop the input rotation.


    Illustration 44g00918765
    Tooling (N)


    Illustration 45g00918767
    ( 25) Engine Output Speed Sensor
    (26) Torque Converter Output Speed Sensor
    (27) Transmission Output Speed Sensor "A"
    (28) Transmission Output Speed Sensor "B"

  2. Use Tooling (N) to measure the resistance of each speed sensor. Measure speed sensors (25), (26), (27), and (28).

  3. Record the values in Table 20.

  4. Verify all test points with the values in Table 20.

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 21.

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

Transmission Bench Test Data Sheet

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

Solenoid Test

Table 7
Measured Resistance (Ω at 25 °C (77 °F)) 
Solenoid  Description  Measured Resistance 
Clutch 1  9 Ω ± 1 Ω 
Clutch 2  9 Ω ± 1 Ω 
Clutch 3  9 Ω ± 1 Ω 
Clutch 4  9 Ω ± 1 Ω 
Clutch 5  9 Ω ± 1 Ω 
Clutch 6  9 Ω ± 1 Ω 
Lockup Clutch  9 Ω ± 1 Ω 
Latching  33 Ω ± 1 Ω 

Table 8
Solenoid Test  Measured Resistance (Ω at 25 °C (77 °F)) 
1 2  3  4  5  6  7  8 

_____ohms
_____ohms  _____ohms  _____ohms  _____ohms  _____ohms  _____ohms  _____ohms 

Start Checks

Table 9
Lubrication Pressure  Input Speed (800 ± 25 rpm)
Lubrication Pressure 41 ± 28 kPa (6 ± 4 psi) 
_______kPa
_______(psi) 

Low Idle Checks

Table 10
Low Idle Checks 
Gear  Cooler Flow  Lube Press  Main Relief Valve Press(1)  Torque Converter Inlet Pressure(2)(3)  Lockup Clutch Press  Latching Rail Press  TC Outlet Press(2)  Output Speed 
170-4861 Torque Converter Outlet Relief Valve 230-3166 Torque Converter Outlet Relief Valve 
26 ± 11 L/min (7 ± 3 US gpm)  34 ± 28 kPa (5 ± 4 psi)  2344 ± 138 kPa (340 ± 20 psi)  255 ± 34 kPa (37 ± 5 psi)  159 ± 34 kPa (23 ± 5 psi)  2344 ± 138 kPa (340 ± 20 psi)  2344 ± 138 kPa (340 ± 20 psi)  62 ± 34 kPa (9 ± 5 psi)   
26 ± 11 L/min (7 ± 3 US gpm)  255 ± 34 kPa (37 ± 5 psi) 159 ± 34 kPa (23 ± 5 psi)  62 ± 34 kPa (9 ± 5 psi) 179 ± 20 rpm
F1  26 ± 11 L/min (7 ± 3 US gpm)  255 ± 34 kPa (37 ± 5 psi) 159 ± 34 kPa (23 ± 5 psi)  62 ± 34 kPa (9 ± 5 psi) 140 ± 10 rpm
F2  23 ± 11 L/min (6 ± 3 US gpm)  241 ± 34 kPa (35 ± 5 psi) 138 ± 34 kPa (20 ± 5 psi)  55 ± 34 kPa (8 ± 5 psi) 224 ± 10 rpm
F3  23 ± 11 L/min (6 ± 3 US gpm)  241 ± 34.5 kPa (35 ± 5 psi) 138 ± 34 kPa (20 ± 5 psi)  55 ± 34 kPa (8 ± 5 psi) 294 ± 10 rpm
F4  23 ± 11 L/min (6 ± 3 US gpm)  241 ± 34 kPa (35 ± 5 psi) 138 ± 34.5 kPa (20 ± 5 psi)  55 ± 34 kPa (8 ± 5 psi) 411 ± 10 rpm
F5  23 ± 11 L/min (6 ± 3 US gpm)  241 ± 34 kPa (35 ± 5 psi) 145 ± 34 kPa (21 ± 5 psi)  55 ± 34 kPa (8 ± 5 psi) 560 ± 10 rpm
F6  20 ± 11 L/min (5 ± 3 US gpm)  228 ± 34 kPa (33 ± 5 psi) 131 ± 34 kPa (19 ± 5 psi)  48 ± 34 kPa (7 ± 5 psi) 800 ± 10 rpm
F7  23 ± 11 L/min (6 ± 3 US gpm)  241 ± 34 kPa (35 ± 5 psi) 145 ± 34 kPa (21 ± 5 psi)  55 ± 34 kPa (8 ± 5 psi) 1088 ± 10 rpm
F8  23 ± 11 L/min (6 ± 3 US gpm)  241 ± 34 kPa (35 ± 5 psi) 145 ± 34 kPa (21 ± 5 psi)  55 ± 34 kPa (8 ± 5 psi) 1268 ± 10 rpm
(1) Supply Pressure
(2) Pressures will be sensitive to tooling conditions. The diameter of the Hose, the diameter of a fitting, and additional filtering can affect pressure.
(3) Service Letter, SEBE8936, "Product Improvement Program for Replacing the Sleeve Bearing in the 135-5564 Torque Converter Shaft Assembly On Certain 735 Articulated Trucks", Service Letter, SEBE9027, "Product Improvement Program for Replacing the Torque Converter Sleeve Bearings and Related Parts On Certain 725 and 730 Articulated Trucks", Service Letter, SEBE8982, "Product Improvement Program for Replacing the Sleeve Bearing in the 135-5564 Torque Converter Shaft Assembly on Certain 735 Articulated Trucks", Service Letter, SEBE9010, "Product Support Program for Repairing the Transmission in Certain 735 Articulated Trucks Due to a Failure of the #2 Clutch Hub" These guidelines recommend the replacement of the Torque Converter Outlet Relief Valve. Use the appropriate test specifications for the Torque Converter Outlet Relief Valve that is used on the transmission that is being tested.

Table 11
Low Idle Checks  Input Speed (800 ± 25 rpm) 
Gear  Cooler Flow

L/min (gpm) 
Lube Pressure

kPa (psi) 
Main Relief Valve Pressure(1)

kPa (psi) 
Torque Converter Inlet Pressure

kPa (psi) 
Lockup Clutch Pressure

kPa (psi) 
Latching Rail Pressure

kPa (psi) 
Torque Converter Outlet Pressure

kPa (psi) 
Output Speed

rpm 

________ 
________  ________  ________    ________  ________  ________ 

________ 
________  ________  ________    ________  ________  ________ 
F1 
________ 
________  ________  ________  ________  ________  ________  ________ 
F2 
________ 
________  ________  ________  ________  ________  ________  ________ 
F3 
________ 
________  ________  ________  ________  ________  ________  ________ 
F4 
________ 
________  ________  ________  ________  ________  ________  ________ 
F5 
________ 
________  ________  ________  ________  ________  ________  ________ 
F6 
________ 
________  ________  ________  ________  ________  ________  ________ 
F7 
________ 
________  ________  ________  ________  ________  ________  ________ 
F8 
________ 
________  ________  ________  ________  ________  ________  ________ 
(1) Supply Pressure

Table 12
Clutch Pressures 
Gear  Clutch 1  Clutch 2  Clutch 3  Clutch 4  Clutch 5  Clutch 6 
          2344 ± 138 kPa (340 ± 20 psi) 
    2344 ± 138 kPa (340 ± 20 psi)      2344 ± 138 kPa (340 ± 20 psi) 
F1        2344 ± 138 kPa (340 ± 20 psi)    2344 ± 138 kPa (340 ± 20 psi) 
F2  2344 ± 138 kPa (340 ± 20 psi)          2344 ± 138 kPa (340 ± 20 psi) 
F3  2344 ± 138 kPa (340 ± 20 psi)      2344 ± 138 kPa (340 ± 20 psi)     
F4  2344 ± 138 kPa (340 ± 20 psi)        2344 ± 138 kPa (340 ± 20 psi)   
F5  2344 ± 138 kPa (340 ± 20 psi)    2344 ± 138 kPa (340 ± 20 psi)       
F6  2344 ± 138 kPa (340 ± 20 psi)  2344 ± 138 kPa (340 ± 20 psi)         
F7    2344 ± 138 kPa (340 ± 20 psi)  2344 ± 138 kPa (340 ± 20 psi)       
F8    2344 ± 138 kPa (340 ± 20 psi)      2344 ± 138 kPa (340 ± 20 psi)   

Table 13
Clutch Pressures 
Gear  Clutch 1  Clutch 2  Clutch 3  Clutch 4  Clutch 5  Clutch 6 
         
___________ 
   
___________ 
   
___________ 
F1       
___________ 
 
___________ 
F2 
___________ 
       
___________ 
F3 
___________ 
   
___________ 
   
F4 
___________ 
     
___________ 
 
F5 
___________ 
 
___________ 
     
F6 
___________ 

___________ 
       
F7   
___________ 

___________ 
     
F8   
___________ 
   
___________ 
 

High Idle Pressure Checks

Table 14
High Idle Checks 
Gear  Cooler Flow  Lube Press  Main Relief Press(1)  Torque Converter Inlet Pressure(2)(3)  Lockup Clutch Press  Latching Rail Press  TC Outlet Press(2)  Max Excess Parasitic Load 
170-4861 Torque Converter Outlet Relief Valve 230-3166 Torque Converter Outlet Relief Valve 
98 ± 11 L/min (26 ± 3 US gpm)  172 ± 34 kPa (25 ± 5 psi)  2482 ± 138 kPa (360 ± 20 psi)  703 ± 34 kPa (102 ± 5 psi)  634 ± 34 kPa (92 ± 5 psi)  2482 ± 138 kPa (360 ± 20 psi)  2482 ± 138 kPa (360 ± 20 psi)  428 ± 34 kPa (62 ± 5 psi)  15 kW (20 hp) 
98 ± 11 L/min (26 ± 3 US gpm)  703 ± 34 kPa (102 ± 5 psi) 634 ± 34 kPa (92 ± 5 psi)  428 ± 34 kPa (62 ± 5 psi) 27 kW (36 hp)
98 ± 11 L/min (26 ± 3 US gpm)  717 ± 34 kPa (104 ± 5 psi) 641 ± 34 kPa (93 ±5 psi)  441 ± 34 kPa (64 ± 5 psi) 28 kW (38 hp)
95 ± 11 L/min (25 ± 3 US gpm)  676 ± 34 kPa (98 ± 5 psi) 586 ± 34 kPa (85 ± 5 psi)  400 ± 34 kPa (58 ± 5 psi) 37 kW (50 hp)
95 ± 11 L/min (25 ± 3 US gpm)  676 ± 34 kPa (98 ± 5 psi) 586 ± 34 kPa (85 ± 5 psi)  400 ± 34 kPa (58 ± 5 psi) 31 kW (41 hp)
95 ± 11 L/min (25 ± 3 US gpm)  676 ± 34 kPa (98 ± 5 psi) 586 ± 34 kPa (85 ± 5 psi)  407 ± 34 kPa (59 ± 5 psi) 25 kW (33 hp)
95 ± 11 L/min (25 ± 3 US gpm)  676 ± 34 kPa (98 ± 5 psi) 586 ± 34 kPa (85 ± 5 psi)  407 ± 34 kPa (59 ± 5 psi) 27 kW (36 hp)
91 ± 11 L/min (24 ± 3 US gpm)  648 ± 34 kPa (94 ± 5 psi) 559 ± 34 kPa (81 ± 5 psi)  379 ± 34 kPa (55 ± 5 psi) 28 kW (37 hp)
95 ± 11 L/min (25 ± 3 US gpm)  676 ± 34 kPa (98 ± 5 psi) 586 ± 34 kPa (85 ± 5 psi)  407 ± 34 kPa (59 ± 5 psi) 34 kW (46 hp)
95 ± 11 L/min (25 ± 3 US gpm)  676 ± 34 kPa (98 ± 5 psi) 586 ± 34 kPa (85 ± 5 psi)  414 ± 34 kPa (60 ± 5 psi) 40 kW (54 hp)
(1) Supply Pressure
(2) Pressures will be sensitive to tooling conditions. The diameter of the Hose, the diameter of a fitting, and additional filtering can affect pressure.
(3) Service Letter, SEBE8936, "Product Improvement Program for Replacing the Sleeve Bearing in the 135-5564 Torque Converter Shaft Assembly On Certain 735 Articulated Trucks", Service Letter, SEBE9027, "Product Improvement Program for Replacing the Torque Converter Sleeve Bearings and Related Parts On Certain 725 and 730 Articulated Trucks", Service Letter, SEBE8982, "Product Improvement Program for Replacing the Sleeve Bearing in the 135-5564 Torque Converter Shaft Assembly on Certain 735 Articulated Trucks", Service Letter, SEBE9010, "Product Support Program for Repairing the Transmission in Certain 735 Articulated Trucks Due to a Failure of the #2 Clutch Hub" These guidelines recommend the replacement of the Torque Converter Outlet Relief Valve. Use the appropriate test specifications for the Torque Converter Outlet Relief Valve that is used on the transmission that is being tested.

Table 15
High Idle Checks  Input Speed (1900 ± 25 rpm)
Downshifts (1450 ± 25 rpm) 
Gear  Cooler Flow

L/min (gpm) 
Lube Pressure

kPa (psi) 
Main Relief Valve Pressure(1)

kPa (psi) 
Torque Converter Inlet Pressure

kPa (psi) 
Lockup Clutch Pressure

kPa (psi) 
Latching Rail Pressure

kPa (psi) 
Torque Converter Outlet Pressure

kPa (psi) 
Parasitic Loss

kW (hp) 

________ 
________  ________  ________    ________  ________  ________ 

________ 
________  ________  ________    ________  ________  ________ 
F1 
________ 
________  ________  ________  ________  ________  ________  ________ 
F2 
________ 
________  ________  ________  ________  ________  ________  ________ 
F3 
________ 
________  ________  ________  ________  ________  ________  ________ 
F4 
________ 
________  ________  ________  ________  ________  ________  ________ 
F5 
________ 
________  ________  ________  ________  ________  ________  ________ 
F6 
________ 
________  ________  ________  ________  ________  ________  ________ 
F7 
________ 
________  ________  ________  ________  ________  ________  ________ 
F8 
________ 
________  ________  ________  ________  ________  ________  ________ 
(1) Supply Pressure

Table 16
Clutch Pressures 
Gear  Clutch 1  Clutch 2  Clutch 3  Clutch 4  Clutch 5  Clutch 6 
          2344 ± 138 kPa (340 ± 20 psi) 
    2344 ± 138 kPa (340 ± 20 psi)      2344 ± 138 kPa (340 ± 20 psi) 
F1        2344 ± 138 kPa (340 ± 20 psi)    2344 ± 138 kPa (340 ± 20 psi) 
F2  2344 ± 138 kPa (340 ± 20 psi)          2344 ± 138 kPa (340 ± 20 psi) 
F3  2344 ± 138 kPa (340 ± 20 psi)      2344 ± 138 kPa (340 ± 20 psi)     
F4  2344 ± 138 kPa (340 ± 20 psi)        2344 ± 138 kPa (340 ± 20 psi)   
F5  2344 ± 138 kPa (340 ± 20 psi)    2344 ± 138 kPa (340 ± 20 psi)       
F6  2344 ± 138 kPa (340 ± 20 psi)  2344 ± 138 kPa (340 ± 20 psi)         
F7    2344 ± 138 kPa (340 ± 20 psi)  2344 ± 138 kPa (340 ± 20 psi)       
F8    2344 ± 138 kPa (340 ± 20 psi)      2344 ± 138 kPa (340 ± 20 psi)   

Table 17
Clutch Pressures 
Gear  Clutch 1  Clutch 2  Clutch 3  Clutch 4  Clutch 5  Clutch 6 
         
___________ 
   
___________ 
   
___________ 
F1       
___________ 
 
___________ 
F2 
___________ 
       
___________ 
F3 
___________ 
   
___________ 
   
F4 
___________ 
     
___________ 
 
F5 
___________ 
 
___________ 
     
F6 
___________ 

___________ 
       
F7   
___________ 

___________ 
     
F8   
___________ 
   
___________ 
 

Pump Flow Check

Table 18
Pump Flow Check  Input Speed (800 ± 25 rpm) 
Lubrication Pressure  Input Speed 

_______kPa (psi) 

_______ rpm 

Speed Sensor Test

Table 19
Speed Sensor Test 
Sensor  Resistance 
Engine Output Speed Sensor
 
150 Ω ± 50 Ω 
Torque Converter Output Speed Sensor
 
150 Ω ± 50 Ω 
Transmission Output Speed Sensor "A"
 
1125 Ω ± 375Ω 
Transmission Output Speed Sensor "B"
 
1125 Ω ± 375Ω 

Table 20
Speed Sensor Test 
Sensor  Resistance 
Engine Output Speed Sensor
 
__________________ Ω 
Torque Converter Output Speed Sensor
 
__________________ Ω 
Transmission Output Speed Sensor "A"
 
__________________ Ω 
Transmission Output Speed Sensor "B"
 
__________________ Ω 

Contamination Control

Table 21
Contamination Control  Sample the test bench oil supply.
*ISO 4406 is 16/13 or better 
________/________Particle Count 

Table 22






______________________________________
Technician
 






______________________________________
Supervisor
 

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