Bench Test Procedure for a 784B, 784C, 785, 785B, 785C,785D, 789, and 789B Off-Highway Truck Transmission{3030, 3073} Caterpillar


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Bench Test Procedure for a 784B, 784C, 785, 785B, 785C,785D, 789, and 789B Off-Highway Truck Transmission{3030, 3073} [REHS1426]
POWER TRAIN
CONTROL GP-TRANSMISSION HYD
Bench Test Procedure for a 784B, 784C, 785, 785B, 785C,785D, 789, and 789B Off-Highway Truck Transmission{3030, 3073}
1.1. Introduction
2.1. Canceled Part Numbers and Replaced Part Numbers
3.1. Important Safety Information
4.1. Collecting the Test Data
5.1. Tools Needed
6.1. Installation Procedure
7.1. Test Procedure
8.2. TA3 Navigation
9.2. Harness Test (TA3 Only)
10.2. Solenoid Test (TA2 Only)
11.2. Start Checks
12.2. Priority Reducing Valve
13.2. Neutralizer Valve
14.2. Lube Circuit Check
15.2. Primary Clutch Pressure Checks
16.2. Final Pressure Checks (Low Idle)
17.2. Dual Stage Relief Valve
18.2. Final Pressure Checks (High Idle)
19.1. Transmission Bench Test Data Sheet
20.2. Solenoid Test
21.2. Priority Reducing Valve
22.2. Neutralizer Valve
23.2. Lube Circuit Check
24.2. Primary Pressure Checks
25.2. Dual Stage Relief Valve
26.2. Final Pressure Checks (Low Idle)
27.2. Final Pressure Checks (High Idle)
28.2. ISO Particle Count
Off-Highway Truck/Tractor:
784B (S/N: 5RK1-UP)
784C (S/N: 2PZ1-UP)
785 (S/N: 8GB1-UP)
785B (S/N: 6HK1-UP)
785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)
785D (S/N: DMC1-UP; MSY1-UP)
789 (S/N: 9ZC1-UP)
789B (S/N: 7EK1-UP)

Introduction

Table 1
Revision     Summary of Changes in REHS1426    
05     Standardized
   
04     Added new introduction and Canceled Part Numbers section.    

© 2015 AVSpare 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 AVSpare: Confidential Yellow.

This special instruction contains the necessary information that is required to bench test a specific transmission arrangement. Refer to Table 2 for the correct arrangements. Bench testing the transmission ensures correct assembly and operation of the component. Rotating a transmission provides the most conclusive evaluation. Testing allows the dealer to ensure that the transmission will operate properly in the machine. The specifications in this guideline are specific to bench testing the component. Every effort has been made in order to provide the most current information that is known to AVSpare. 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 AVSpare.

For questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. In order to address an urgent issue, use the following resources in order to communicate your request to AVSpare Repair Process Engineering:

  • AVSpare Dealer Technical Communicator

  • Dealer Solution Network

  • AVSpare Technical Representative

  • Knowledge Network

Table 2
Machine Model     Transmission Arrangement    
784B     3T-0034    
784C     3T-0034    
785     3T-0030, 3T-0034    
785B     3T-0034    
785C     3T-0034    
789     3T-0034    
789B     3T-0034    

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 in order to perform maintenance, repair, or operate any machine. Safety precautions and warnings are provided this instruction and on AVSpare products. These warnings should be observed before performing any procedures. AVSpare 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.

AVSpare 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. AVSpare 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 in order 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

Table 3
Required Tools    
Tool     Part Number     Part Description     Qty    
A     1U-9584     Rail As     1    
1U-9586 Swivel Head Support Gp     1    
1U-9585 Block Gp (Transmission Mounting)     1    
B     1U-8847     Adapter Plate     1    
2H-3740 Bolt (3/4-16X1.25 inch)        
C     1U-9131     Drive Adapter (Key) (1)     1    
D     1U-9359     Drive Adapter (2)     1    
E     1U-5935     Plate As (Spindle Adapter)     1    
0L-1178 Bolt (3/4-10X2.0 inch)     2    
5P-8248 Hard Washer     2    
2J-3506 Full Nut     2    
1B-4367 Bolt (5/8-11X3.0 inch)     2    
4B-5275 Washer     2    
1D-4720 Nut     2    
5D-6428 O-Ring Seal     1    
F     1U-9722     Load Binder As (Ratchet Type)     4    
439-3940 Link Bracket As     2    
1B-4367 Bolt (5/8-11X3.0 inch)     2    
G     1U-5999     Spindle Gp     1    
8B-7997 Bolt (1/2-13X2.0 inch)     4    
H     1U-8654     Adapter (Splined)     1    
S     3B-6552     Elbow     1    
3B-7282 Pipe Nipple     1    
6V-4142 Fitting (Test)     1    
J     4C-4898     Cover (Transmission Test)     1    
K     1U-8304     Fitting     2    
9U-7446 Adapter     2    
1P-4579 Half Flange     4    
8C-9024 Fitting As (Plain)     2    
6V-3965 Fitting As (Quick Disconnect)     2    
3J-1907 O-Ring Seal     2    
7X-0325 Bolt (1/2-13X2.5 inch)     8    
8T-4223 Hard Washer     8    
L     5T-7967     Adapter     1    
5F-8807 Bolt (1/2-13X1.25 inch)     4    
M     1U-8301     Fitting     1    
9U-7446 Adapter     1    
1P-4579 Half Flange     2    
8C-9024 Fitting As (Plain)     1    
6V-3965 Fitting As (Quick Disconnect)     1    
3J-1907 O-Ring Seal     1    
9S-1366 Bolt (1/2-13X1.25 inch)     4    
8T-4223 Hard Washer     4    
N     6V-3965     Fitting As     1    
3J-1907 O-Ring Seal     1    
T     8J-7844     Adapter Fitting     1    
6V-3966 Fitting As (Valve)     1    
3K-0360 O-Ring Seal     1    
P     9U-7500     Transmission Analyzer Tool Gp     1    
OR
277-2362 Transmission Analyzer III Gp     1    
306-0397 Extension Cable (Transmission Analyzer)     1    
1U-9482 Adapter Cable As     1    
4C-5974 Cable Adapter     1    
Q     8T-0855     Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))     10    
6V-3989 Fitting (Test)     10    
177-7861 Hose As     10    
6V-4143 Coupler     20    
R     8T-0863     Pressure Gauge (0 to 250 kPa (0 to 36 psi))     2    
6V-3989 Fitting (Test)     2    
177-7861 Hose As     2    
6V-4143 Coupler     4    
( 1 ) This drive adapter is used with the small drive shaft.
( 2 ) This drive adapter is used with the large drive shaft.

Installation Procedure




    Illustration 3g03862132

  1. Install Tooling (A) to the test bench.



    Illustration 4g00913598

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



    Illustration 5g00913599

  1. Install Tooling (B) to the input yoke.



    Illustration 6g00913600

  1. Install Tooling (C) on Tooling (B) .

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




    Illustration 7g00913601

  1. Align the transmission with the input drive shaft.

  1. Connect the input drive shaft to Tooling (C) .



    Illustration 8g00913602

  1. Install the drive shaft guard.



    Illustration 9g03802221

  1. Tighten all four castle nuts and jack bolts.



    Illustration 10g00913603

  1. Use a hoist to install Tooling (E) on the transmission case. The weight of Tooling (E) is 50 kg (110 lb).



    Illustration 11g00913604

  1. Install two bolts in the bottom locations.



    Illustration 12g00913605



    Illustration 13g00913606

  1. Install Tooling (F) in the top locations.



    Illustration 14g00913607

  1. Install Tooling (F) to the input and output ends of the transmission.



    Illustration 15g00913608

    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.

  1. Remove the drawbar bolt from Tooling (G) .



    Illustration 16g00913609

  1. Lubricate the outer diameter of Tooling (H) .

  1. Install Tooling (H) in Tooling (G) .

  1. Install the drawbar bolt. Tighten the drawbar bolt to retain Tooling (H) in Tooling (G). The correct torque is 170 N·m (125 lb ft).



    Illustration 17g00913613

  1. Use a hoist to install Tooling (G) on Tooling (E). The weight of Tooling (G) is 121 kg (267 lb).

  1. Carefully install Tooling (G) on Tooling (E). Tooling (H) will slide on the transmission output shaft.



    Illustration 18g00913615

  1. Loosen bolt (1) .



    Illustration 19g00913616

  1. Use bolt (2) to adjust Tooling (G) inward until Tooling (H) contacts the carrier.

    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.

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

    Note: The measurement may be taken through the access hole in Tooling (E) .

  1. Tighten bolt (1) .



    Illustration 20g00913659

  1. Remove bracket (3) .



    Illustration 21g00913660

  1. Remove cover (4) .



    Illustration 22g00913663

  1. Remove plug (5) .



    Illustration 23g03861353

  1. Install Tooling (S) .



    Illustration 24g00913668

  1. Install Tooling (J) .



    Illustration 25g00913618

  1. Install Tooling (K) .



    Illustration 26g00913669

  1. Install Tooling (L) .



    Illustration 27g00914112

  1. Install Tooling (M) to Tooling (L) .



    Illustration 28g00913683

  1. Remove filter assembly (6) .



    Illustration 29g00913685

  1. Remove drain plug (7) .



    Illustration 30g00913686

  1. Remove plug (8) .



    Illustration 31g00913688

  1. Install Tooling (N) .



    Illustration 32g00913691

  1. Remove fitting (9) .



    Illustration 33g03861364

  1. Install Tooling (T) .



    Illustration 34g00913698

    Supply Oil

  1. Connect hose assembly (10) from the pressurized flow meter to Tooling (K) .



    Illustration 35g00913699

    Oil Cooler Outlet

  1. Connect hose assembly (11) from Tooling (K) to No. 2 flow meter inlet.

    Note: The No. 2 flow meter will measure the output flow that is returning to the transmission lubrication port.




    Illustration 36g00913700

    Transmission Lubrication

  1. Connect hose assembly (12) from the outlet of the No. 2 flow meter to Tooling (M) .



    Illustration 37g00913706

  1. Connect lube line (13) from the test bench to Tooling (G). Maintain an oil pressure of 275 kPa (40 psi).



    Illustration 38g00913718

    (14) Pressure tap "A" for the No. 2 clutch

    (15) Pressure tap "B" for the No. 1 clutch

    (16) Pressure tap "C" for the No. 3 clutch

    (17) Pressure tap "D" for the lockup dual stage relief valve

    (18) Pressure tap "E" for the No. 4 clutch

    (19) Pressure tap "F" for the No. 5 clutch

    (20) Pressure tap "G" for the No. 6 clutch

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

  1. Connect Tooling (Q) to pressure taps (14), (15), (16), (17), (18), (17), and (18) .

    Note: Pressure tap "H" is not used.




    Illustration 39g03861586

    Pressure tap for the pilot oil pressure

  1. Connect Tooling (Q) to Tooling (S) .



    Illustration 40g03861365

    Pressure tap for the transmission charge pump

  1. Connect Tooling (Q) to Tooling (T) .



    Illustration 41g00913737

    (21) Pressure tap for the lockup clutch pressure

  1. Connect Tooling (Q) to pressure tap (21) .



    Illustration 42g00913741

    (22) Pressure tap for the transfer gear lube

  1. Connect Tooling (R) to pressure tap (22) .



    Illustration 43g00913746

    Pressure tap for the planetary lube circuit

  1. Connect Tooling (R) to Tooling (N) .



    Illustration 44g00913748

    (24) Upshift Solenoid

    (25) Downshift Solenoid

    (26) Lockup Clutch Solenoid

  1. Connect Tooling (P) to solenoid (24), solenoid (25), and solenoid (26) .



    Illustration 45g00913752

  1. Connect Tooling (P) to harness connector (27) .



    Illustration 46g00913753

  1. Connect Tooling (P) to a suitable location.



    Illustration 47g00877510

    Tooling (P)




    Illustration 48g01457869

    Tooling (P)

  1. 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

TA3 Navigation

  1. Select "Off-Highway Trucks".

  1. Select "784B-24V", "784C-24V", "785-24V", "785B-24V", "785C-24V", "789-24V"or "789B-24V".

Harness Test (TA3 Only)

  1. Make sure that the harness is properly connected.

  1. Use Tooling (P) to perform the harness test.

  1. Record the values in Table 6.

    Note: Do not continue testing until Harness Test passes.

Solenoid Test (TA2 Only)

  1. Make sure that the harness is properly connected.

  1. Use Tooling (P) to perform the solenoid test.

  1. Record the values in Table 6.

    Note: Do not continue testing until Solenoid Test passes.

Start Checks

------ 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.

----------------------

    Note: Refer to Testing and Adjusting, SENR6327, "789B Off-Highway Truck Power Train" for the correct adjusting procedures.

  1. If you are using SAE 10W oil, warm the oil to 50 °C (125 °F). If you are using Mobil DTE11 oil, warm the oil to 34 °C (95 °F). Maintain this temperature for the duration of the test.

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



    Illustration 49g02720621

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

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

  1. Confirm the correct clutch engagement with Table 4.

    Table 4
    Clutch Engagement Check    
    Gear     Cl 1     Cl 2     Cl 3     Cl 4     Cl 5     Cl 6    
    N1             X                
    N2     X                        
    R     X                     X    
    F1     X                 X        
    F2         X             X        
    F3     X             X            
    F4         X         X            
    F5     X         X                
    F6         X     X                

  1. Adjust the input rotation to 0 rpm.

  1. Use the following procedure to test the transmission.

Priority Reducing Valve

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

  1. Adjust the input rotation to 700 ± 30 rpm in the NEUTRAL 2 position.

  1. Shift the transmission to the FORWARD 1 position.

  1. Check the pressure for the priority reducing valve. The correct pressure must be 1725 ± 70 kPa (250 ± 10 psi).

  1. Record the value in Table 7.

Neutralizer Valve

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

  1. Stop the input rotation in any range. Do not stop the input rotation in NEUTRAL 1 or NEUTRAL 2. Stop input flow to the transmission.

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

  1. Adjust the input rotation to 700 ± 30 rpm.

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

  1. Record the values in Table 8.

  1. Shift the transmission to the NEUTRAL 1 position. The clutch pressure that is measured at pressure tap "C" must rise to a normal pressure.

  1. Record the value in Table 9.

Lube Circuit Check

  1. Shift the transmission to FORWARD 2.

  1. Adjust the input rotation to 1850 ± 30 rpm.

  1. Adjust the input flow until the lube flow is 152 ± 4 L/min (40 ± 1 US gpm). Maintain this flow during this check.

  1. The lubrication pressure must be within 7 kPa (1 psi) of the average for this arrangement. The reference for the transfer gear lube is 38 ± 7 kPa (5.5 ± 1 psi). The reference for the planetary lube circuit is 41 ± 7 kPa (6 ± 1 psi).

  1. Record the value in Table 10.

  1. Stop the input rotation.

  1. Stop the input flow.

Primary Clutch Pressure Checks

  1. Remove Tooling (J) .



    Illustration 50g00913757

  1. Remove the load piston plugs (28) from selector valve "A", "B", "C", "E", "F", and "G".

    Note: DO NOT remove the load piston plug from selector valve "D".

  1. Install Tooling (H) .

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

  1. The lockup solenoid must be de-energized.

  1. Adjust the input rotation to 700 ± 30 rpm.

  1. Shift the transmission through each gear range.

  1. Record the primary clutch pressure for each gear range in Table 12.

  1. Verify that the primary clutch pressures match the values in Table 11.

Final Pressure Checks (Low Idle)

  1. Install load piston plugs (12). Refer to Special Instruction, "Primary Clutch Pressure Checks".

  1. Install Tooling (J) .

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

  1. Adjust the input rotation to 700 ± 30 rpm.

  1. Shift the transmission through ranges NEUTRAL 2, REVERSE, and FORWARD 1.

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

  1. Record the clutch pressure for each gear range in Table 15.

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

Dual Stage Relief Valve

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

  1. Energize the lockup clutch solenoid.

  1. Disconnect the harness connector from the lockup clutch solenoid.

  1. Adjust the input rotation to 700 ± 30 rpm.

  1. Shift the transmission to the FORWARD 2 position.

  1. Check the pump pressure. The minimum pump pressure is 2515 kPa (365 psi).

  1. Record the value in Table 13.

  1. Adjust the input flow to 150 ± 4 L/min (39 ± 1 US gpm).

  1. Adjust the input rotation to 1850 ± 30 rpm.

  1. Check the pump pressure. Reference is 3070 kPa (445 psi).

  1. Record the value in Table 13.

  1. Connect the harness connector to the lockup clutch solenoid.

  1. Check the pump pressure. The pump pressure is 2100 ± 105 kPa (305 ± 15 psi).

  1. Record the value in Table 13.

  1. If the pump pressure is not correct, adjust the pressure. Refer to Testing and Adjusting, SENR6327, "789B Off-Highway Truck Power Train" for the correct adjusting procedures.

  1. Disconnect the harness connector to the lockup clutch solenoid.

  1. Check the pump pressure. The pump pressure should be 3070 kPa (445 psi).

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

  1. Adjust the input rotation to 800 ± 30 rpm.

  1. Check the pump pressure. The pump pressure should be 2760 kPa (400 psi).

  1. Record the value in Table 13.

Final Pressure Checks (High Idle)

  1. The lockup clutch solenoid must be de-energized.

  1. Adjust the input flow to 150 ± 4 L/min (39 ± 1 US gpm).

  1. Adjust the input rotation to 800 ± 30 rpm with the transmission in the NEUTRAL 1 position.

  1. Adjust the input rotation to 1850 ± 30 rpm.

  1. Record the clutch pressure in Table 17.

  1. Adjust the input rotation to 800 ± 30 rpm.

  1. Shift the transmission through positions NEUTRAL 2, REVERSE, and FORWARD 1. Repeat Steps 4 through 6 for each gear range.

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

  1. Adjust the input rotation to 800 ± 30 rpm with the transmission in the FORWARD 1 position.

  1. Energize the lockup clutch solenoid.

  1. Adjust the input rotation to 1850 ± 30 rpm.

  1. Record the clutch pressure in Table 17.

  1. Adjust the input rotation to 800 ± 30 rpm.

  1. Shift the transmission through positions FORWARD 1, FORWARD 2, FORWARD 3, FORWARD 4, FORWARD 5, and FORWARD 6. Repeat Steps 10 through 12 for each gear range.

  1. Verify that the clutch pressures match the values in Table 16.

Transmission Bench Test Data Sheet

Table 5
AVSpare     Transmission Bench Test Data Sheet     Test Date:_______    
Model:_______
Work Order:_______     Serial No.:_______    

Solenoid Test

Table 6
Solenoid Test     Solenoid 1     Solenoid 2     Solenoid 3    

_______ Ω

_______ Ω    

_______ Ω    

Priority Reducing Valve

Table 7
Priority Reducing Valve     Input Speed (700 ± 30 rpm)
Input Flow
57 ± 4 L/min (15 ± 1 US gpm)    
_______kPa
_______(psi)    

Neutralizer Valve

Table 8
Neutralizer Valve (Step 1)     Input Speed (700 ± 30 rpm)
Input Flow
57 ± 4 L/min (15 ± 1 US gpm)    
A     B     C     D     E     F     G    
_______kPa
_______(psi)    
_______kPa
_______(psi)    
_______kPa
_______(psi)    
_______kPa
_______(psi)    
_______kPa
_______(psi)    
_______kPa
_______(psi)    
_______kPa
_______(psi)    

Table 9
Neutralizer Valve (Step 2)     Gear Range NEUTRAL 1    
Station     C     _____kPa
_____(psi)    
The clutch pressure must rise to normal pressure.     Yes     No    

Lube Circuit Check

Table 10
Lube Circuit Check     Gear Range FORWARD 2
Input Speed (1850 ± 30 rpm)
Lube Flow
152 ± 4 L/min (40 ± 1 US gpm)    
Test Bench Average     Average     Actual    
Transfer Gear Lube Pressure     _______kPa
_______(psi)    
_______kPa
_______(psi)    
Planetary Lube Circuit Pressure     _______kPa
_______(psi)    
_______kPa
_______(psi)    

Primary Pressure Checks

Table 11
Primary Clutch Pressure In Torque Converter Drive    
Station (1) (2)     "A"     "B"     "C"     "E"     "F"     "G"    
Clutch     No. 2     No. 1     No. 3     No. 4     No. 5     No. 6    
Speed Position     Engaged Clutches     Pressure (3)     Pressure (3)     Pressure (3)     Pressure (3)     Pressure (3)     Pressure (3)    
NEUTRAL 1     3     0     0    
480 kPa (70 psi)    
0     0     0    
NEUTRAL 2     1     0    
475 kPa (69 psi)    
0     0     0     0    
REVERSE     1 and 6     0    
475 kPa (69 psi)    
0     0     0    
425 kPa (62 psi)    
FORWARD 1     1 and 5     0    
475 kPa (69 psi)    
0     0    
450 kPa (65 psi)    
0    
FORWARD 2     2 and 5    
525 kPa (76 psi)    
0     0     0    
450 kPa (65 psi)    
0    
FORWARD 3     1 and 4     0    
475 kPa (69 psi)    
0    
425 kPa (62 psi)    
0     0    
FORWARD 4     2 and 4    
525 kPa (76 psi)    
0     0    
425 kPa (62 psi)    
0     0    
FORWARD 5     1 and 3     0    
475 kPa (69 psi)    

480 kPa (70 psi)    
0     0     0    
FORWARD 6     2 and 3    
525 kPa (76 psi)    
0    
480 kPa (70 psi)    
0     0     0    
( 1 ) Station "H" is not used.
( 2 ) Station "D" does not control a clutch. When the lockup clutch solenoid is activated, Station "D" reduces the pressure setting of the dual stage relief valve. The action of Station "D" on the ICM transmission hydraulic control maintains the oil in the clutch supply rail at a reduced pressure. Refer to the Testing and Adjusting, "Transmission Hydraulic Control (Pressure Pack) - Test and Adjust" for the proper procedure to adjust Station "D".
( 3 ) The tolerance is + 50 − 35 kPa (+ 7 − 5 psi).

Table 12
Primary Pressure Checks     The Load Pistons are Removed.
Input Speed (700 ± 30 rpm)
Input Flow
57 ± 4 L/min (15 ± 1 US gpm)    
Station     Clutch     Specification (1)     Original Pressure     Amount of Adjustment     Last Pressure    
A     2    
525 kPa (76 psi)    
           
B     1    
475 kPa (69 psi)    
           
C     3    
480 kPa (70 psi)    
           
E     4    
425 kPa (62 psi)    
           
F     5    
450 kPa (65 psi)    
           
G     6    
425 kPa (62 psi)    
           
( 1 ) The tolerance is + 50 − 35 kPa (+ 7 − 5 psi).

Dual Stage Relief Valve

Table 13
Dual Stage Relief Valve     Input Speed (800 ± 30 rpm)
Input Flow
57 ± 4 L/min (15 ± 1 US gpm)
MIN
2515 kPa (365 psi)    
_______kPa
_______(psi)    
Input Speed (1850 ± 30 rpm)
Input Flow
148 ± 4 L/min (39 ± 1 US gpm)
REFERENCE
3070 kPa (445 psi)
_______kPa
_______(psi)    
Input Speed (1850 ± 30 rpm)
Input Flow
148 ± 4 L/min (39 ± 1 US gpm)
REFERENCE
2100 kPa (305 psi)
Direct Drive
_______kPa
_______(psi)    
Input Speed (800 ± 30 rpm)
Input Flow
57 ± 4 L/min (15 ± 1 US gpm)
REFERENCE
2760 kPa (400 psi)
Direct Drive
_______kPa
_______(psi)    

Final Pressure Checks (Low Idle)

Table 14
Clutch Pressure in Torque Converter Drive With The Engine At Low Idle rpm    
Station (1) (2)     "A"     "B"     "C"     "E"     "F"     "G"    
Clutch     No. 2     No. 1     No. 3     No. 4     No. 5     No. 6    
   
Speed Position     Engaged Clutches     Pressure (3)     Pressure (3)     Pressure (3)     Pressure (3)     Pressure (3)     Pressure (3)    
NEUTRAL 2     1     0    
2760 kPa (400 psi)    
0     0     0     0    
REVERSE     1 and 6     0    
2760 kPa (400 psi)    
0     0     0    
2760 kPa (400 psi)    
FORWARD 1     1 and 5     0    
2760 kPa (400 psi)    
0     0    
2705 kPa (392 psi)    

0    
( 1 ) Station "H" is not used.
( 2 ) Station "D" does not control a clutch. When the lockup clutch solenoid is activated, Station "D" reduces the pressure setting of the dual stage relief valve. The action of Station "D" on the ICM transmission hydraulic control maintains the oil in the clutch supply rail at a reduced pressure. Refer to the Power Train Testing and Adjusting, "Transmission Hydraulic Control (Pressure Pack) - Test and Adjust" for the proper procedure to adjust Station "D".
( 3 ) The tolerance is + 240 − 100 kPa (+ 35 − 15 psi).

Table 15
Final Pressure Checks (Low Idle)     Install the Load Pistons.
Input Speed (700 ± 30 rpm)
Lube Flow
57 ± 4 L/min (15 ± 1 US gpm)    
Station     "A"     "B"     "C"     "E"     "F"     "G"    
Clutch     No. 2     No. 1     No. 3     No. 4     No. 5     No. 6    
Torque Converter Drive    
Speed Position     Engaged Clutches     Pressure     Pressure     Pressure     Pressure     Pressure     Pressure    
NEUTRAL 2     1         _______                

   
REVERSE     1 and 6         _______                
_______
   
FORWARD 1     1 and 5         _______             _______    

   

Final Pressure Checks (High Idle)

Table 16
Clutch Pressure With The Engine At High Idle rpm    
Station (1) (2)     "A"     "B"     "C"     "E"     "F"     "G"    
Clutch     No. 2     No. 1     No. 3     No. 4     No. 5     No. 6    
Torque Converter Drive    
Speed Position     Engaged Clutches     Pressure (3)     Pressure (3)     Pressure (3)     Pressure (3)     Pressure (3)     Pressure (3)    
NEUTRAL 1     3     0     0    
2470 kPa (358 psi)    
0     0     0    
NEUTRAL 2     1     0    
2890 kPa (419 psi)    
0     0     0     0    
REVERSE     1 and 6     0    
2890 kPa (419 psi)    
0     0     0    
2805 kPa (407 psi)    
FORWARD 1     1 and 5     0    
2890 kPa (419 psi)    
0     0    
2705 kPa (392 psi)    
0    
Direct Drive    
FORWARD 1     1 and 5     0    
2020 kPa (293 psi)    
0     0    
2020 kPa (293 psi)    
0    
FORWARD 2     2 and 5    
2020 kPa (293 psi)    
0     0     0    
2020 kPa (293 psi)    
0    
FORWARD 3     1 and 4     0    
2020 kPa (293 psi)    
0    
2020 kPa (293 psi)    
0     0    
FORWARD 4     2 and 4    
2020 kPa (293 psi)    
0     0    
2020 kPa (293 psi)    
0     0    
FORWARD 5     1 and 3     0    
2020 kPa (293 psi)    

2020 kPa (293 psi)    
0     0     0    
FORWARD 6     2 and 3    
2020 kPa (293 psi)    
0    
2020 kPa (293 psi)    
0     0     0    
( 1 ) Station "H" is not used.
( 2 ) Station "D" does not control a clutch. When the lockup clutch solenoid is activated, Station "D" reduces the pressure setting of the dual stage relief valve. The action of Station "D" on the ICM transmission hydraulic control maintains the oil in the clutch supply rail at a reduced pressure. Refer to the Power Train Testing and Adjusting, "Transmission Hydraulic Control (Pressure Pack) - Test and Adjust" for the proper procedure to adjust Station "D".
( 3 ) The tolerance is + 240 − 100 kPa (+ 35 − 15 psi).

Table 17
Final Pressure Checks (High Idle)     Input speed (1850 ± 30 rpm)
Input flow
150 ± 4 L/min (39 ± 1 US gpm)    
Station     "A"     "B"     "C"     "E"     "F"     "G"    
Clutch     No. 2     No. 1     No. 3     No. 4     No. 5     No. 6    
Torque Converter Drive    
Speed Position     Engaged Clutches     Pressure     Pressure     Pressure     Pressure     Pressure     Pressure    
NEUTRAL 1     3             _______            

   
NEUTRAL 2     1         _______                

   
REVERSE     1 and 6         _______                
_______
   
FORWARD 1     1 and 5         _______             _______    

   
Direct Drive    
FORWARD 1     1 and 5         _______             _______    

   
FORWARD 2     2 and 5     _______                 _______    

   
FORWARD 3     1 and 4         _______         _______        

   
FORWARD 4     2 and 4     _______             _______        

   
FORWARD 5     1 and 3         _______     _______            

   
FORWARD 6     2 and 3     _______         _______            

   

ISO Particle Count

Table 18
ISO Particle Count     Sample the test bench oil supply.    
________/________Particle Count    

Table 19






______________________________________
Technician
   






______________________________________
Supervisor
   

Information System:

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