- Articulated Truck
- 735 (S/N: B1N1-UP; AWR1-UP)
Introduction
Revision | Summary of Changes in REHS1409 | |
07 | Added Arrangement Number
Added Serial Number Prefix B1N |
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06 | Standardized. | |
05 | Updated Introduction.
Added "Think Safety' graphic. Updated Table 5. |
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04 | Updated introduction and added 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 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 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. to address an urgent need, use the following resources to communicate your request to AVSpare Repair Process Engineering:
- Cat Dealer Techinical Communicator
- Dealer Solution Network
- Cat Technical Representative
- Knowledge Network
Machine Model | Transmission Arrangement |
735 |
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 1 | g02139237 |
Follow all safety warnings. Most accidents that involve product operation, maintenance, or repair are caused by failure to observe safety warnings. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. Personnel must be properly trained to perform maintenance, repair, or operate any machine. Safety precautions and warnings are provided this instruction and on 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.
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Illustration 2 | g00008666 |
This safety alert symbol means:
Pay Attention!
Become Alert!
Your Safety is Involved.
The message that appears under the safety alert symbol explains the hazard.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
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 to compare values on portions of this transmission test. Always compare data that is collected from the same transmission arrangement that is being tested. Averages for the last 20 transmission arrangements should be maintained.
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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. |
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Personal injury or death can result from not following the proper procedures. To avoid the possibility of injury or death, follow the established procedure. |
Tools Needed
Note: Pressures will be sensitive to tooling setup. The diameter of the hose, the diameter of a fitting, and additional filtering can affect pressure. The required tools that are listed in Table 3 were used to develop this test procedure. For additional information about tooling, consult AVSpare Service Tools Division.
Required Tools | |||
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Tool | Part Number | Part Description | Qty |
A | Rail As | 2 | |
Support | 1 | ||
Bolt (5/8-11X3.50 inch) | 10 | ||
Washer | 8 | ||
Full Nut | 10 | ||
Bolt (M16X2.0X50 mm) | 4 | ||
Lockwasher | 4 | ||
Bolt (M20X2.5X140 mm) | 2 | ||
Hard Washer | 2 | ||
Link Bracket As | 4 | ||
Bracket As (TEST) | 2 | ||
B | Drive Adapter | 1 | |
Bolt (M12X1.25X35 mm) | 6 | ||
C | Spindle Adapter | 1 | |
Bolt (3/8-16X1.75 inch) | 4 | ||
Lockwasher | 4 | ||
D | Spindle Gp | 1 | |
Bolt (1/2-13X2.00 inch) | 4 | ||
Lockwasher | 4 | ||
E | Adapter As | 1 | |
F | Drive Adapter (KEY) | 1 | |
G | Drive Adapter | 1 | |
H | Load Binder As (RATCHET TYPE) | 3 | |
Link Bracket As | 2 | ||
Bolt (M12X1.75X30 mm) | 2 | ||
Hard Washer | 2 | ||
Full Nut | 2 | ||
P | Suction Adapter Gp | 1 | |
Bolt (M10X1.50X25 mm) | 4 | ||
Washer | 4 | ||
J | Fitting | 2 | |
Adapter | 2 | ||
Half Flange | 4 | ||
Fitting As (PLAIN) | 2 | ||
Bolt (M10X1.50X35 mm) | 8 | ||
Washer | 8 | ||
Fitting As (TEST) | 2 | ||
O-Ring Seal | 1 | ||
K | Transmission Analyzer Tool Gp | 1 | |
OR | |||
Transmission Analyzer III Gp | 1 | ||
Extension Cable | 1 | ||
Cable (TEST) | 1 | ||
Cable Adapter | 6 | ||
L | Pressure Gauge (0 to 4,000 kPa (0 to 580 psi)) | 8 | |
Pressure Gauge (0 to 1,000 kPa (0 to 145 psi)) | 2 | ||
Pressure Gauge (-100 to 500 kPa (-15 to 72 psi)) | 2 | ||
Pressure Gauge (0 to 250 kPa (0 to 36 psi)) | 1 | ||
Coupler | 13 | ||
M | Multitach II Group | 1 | |
N | Connecting Plug Kit | 1 | |
Connector Socket | 2 | ||
Electrical Wire (18 AWG) | 1 | ||
Plug Assembly (Double Banana)(1) | 1 | ||
Digital Multimeter | 1 |
(1) | Pomona Model 1330-0 |
Installation Procedure
- Assemble Tooling (A).
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Illustration 4 g00915751 - Install Tooling (A) to the output end of the transmission.
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Illustration 5 g00915752 - Use a hoist to install the transmission on the test bench. The weight of the transmission is
950 kg (2094 lb) .Show/hide tableIllustration 6 g00915754 - Install Tooling (A) to the input end of the transmission.
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Illustration 7 g00915755 - Install Tooling (A) to the output end of the transmission.
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Illustration 8 g00915756 - If necessary, remove the flex plate from the torque converter.
- Install Tooling (B) to the torque converter.
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Illustration 9 g00915758 - Install Tooling (C) to the transmission case.
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Illustration 10 g00915760 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.
- Install Tooling (D) on Tooling (C).
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Illustration 11 g00915764 - Tighten the collet on Tooling (D) to connect Tooling (D) to Tooling (B).
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Illustration 12 g00915766 - Install Tooling (E) to the input shaft of Tooling (D).
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Illustration 13 g00915768 - 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).
Show/hide tableIllustration 14 g00915772 - Align the transmission with the input drive shaft.
- Connect the input drive shaft to Tooling (F).
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Illustration 15 g00915774 - Install the drive shaft guard.
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Illustration 16 g03802221 - Tighten all four castle nuts and jack bolts.
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Illustration 17 g00878734 Input end of transmission - Install Tooling (H) to the input end of the transmission.
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Illustration 18 g00915777 Output end of transmission - Install Tooling (H) to the output end of the transmission.
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Illustration 19 g06000482 - Remove the plate from the oil pan.
- Install Tooling (P) on the oil sump.
Note: The rubber hose will fit over the sump. The brackets will secure the tooling.
Show/hide tableIllustration 20 g00915783 - Install Tooling (J).
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Illustration 21 g00915787 - Connect hose assembly (1) from the pump supply to Tooling (P).
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Illustration 22 g00915790 - 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.
Show/hide tableIllustration 23 g00915791 - Connect hose assembly (3) from the No. 2 flow meter outlet to Tooling (J).
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Illustration 24 g00915793 - Connect lube line (4) from the test bench to Tooling (D). Maintain an oil pressure of
275 kPa (40 psi) .Show/hide tableIllustration 25 g00915797 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) - Connect Tooling (K) to six clutch solenoids.
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Illustration 26 g00878743 Cable connector (7-G) for lockup clutch solenoid (11) - Connect Tooling (K) to lockup clutch solenoid (11).
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Illustration 27 g00878744 Cable connector (8-H) for latching solenoid (12) Note: Perform this step if your transmission arrangement is equipped with a latching system.
- Connect Tooling (K) to latching solenoid (12).
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Illustration 28 g00878745 Tooling (K) - Connect Tooling (K) to a suitable location.
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Illustration 29 g00878746 (13) Transmission Hydraulic Control Relief Valve
(14) Torque Converter Inlet PressureNote: If you are using individual pressure gauges to measure the pressures, refer to Table 3 for the correct pressure gauges.
- Connect a pressure gauge to pressure tap (13).
- Connect a pressure gauge to pressure tap (14).
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Illustration 30 g00915811 (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 - Connect six pressure gauges to pressure taps (15), (16), (17), (18), (19), and (20).
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Illustration 31 g00915824 (21) Lockup Clutch Pressure - Connect a pressure gauge to pressure tap (21).
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Illustration 32 g00915825 (22) Latching Rail Pressure - Connect a pressure gauge to pressure tap (22).
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Illustration 33 g00915828 (23) Torque Converter Outlet Pressure - Connect a pressure gauge to pressure tap (23).
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Illustration 34 g00915831 (24) Lubrication Pressure - Connect a pressure gauge to pressure tap (24).
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Illustration 35 g00915833 Tooling (M) Show/hide tableIllustration 36 g06003033 Tooling (M) - Install Tooling (M) on the output yoke.
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Illustration 37 g00877510 Tooling (K) Show/hide tableIllustration 38 g01457869 Tooling (K) - 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.
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Illustration 3 | g06000480 |
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.
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.
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Illustration 39 | g00878491 |
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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 harness failure.
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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.
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Illustration 40 | g00878493 |
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Use the "N" key to shift the transmission to NEUTRAL. |
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Illustration 41 | g00878495 |
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Use the "UP CURSOR" key to upshift the transmission to the next higher gear range. |
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Illustration 42 | g00915664 |
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Use the "DOWN CURSOR" key to downshift the transmission to the next lower gear range. |
TA3 Navigation
- Select “Articulated Trucks”.
- Select “735-24V”.
Harness Test (TA3 only)
- Make sure that the harness is properly connected.
- Use Tooling (K) to perform the harness test.
- Record the values in Table 8.
Note: Do not continue testing until Harness Test passes.
Solenoid Test (TA2 only)
- Make sure that the harness is properly connected.
- Use Tooling (K) to perform the solenoid test.
- Record the values in Table 8.
Note: Do not continue testing until Solenoid Test passes.
Start Checks
- 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 to34 °C (95 °F) . Maintain this temperature for the duration of the test.Show/hide tableIllustration 43 g02720621 Note: The transmission must be in the NEUTRAL position.
- 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.
- 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.
- Record the value in Table 9.
- Shift the transmission through all gear ranges to eliminate air from the transmission controls.
- Verify that the active clutches are correct for each gear range. Refer to Table 4.
- Verify that the output speeds match the values in Table 4.
Clutch Engagement Check | |||||||||||||||
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Gear | Clutches | Output Speed(1) | Output Speed (2) | ||||||||||||
1 | 2 | 3 | 4 | 5 | 6 | L U C |
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N | X | ||||||||||||||
R | 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
- Adjust the input rotation to 800 ± 25 rpm in the NEUTRAL position.
- Shift the transmission through each gear range.
Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.
- Record the values in Table 11 and 13.
- Verify all test points with the values in Table 10 and Table 12.
Note: Make all shifts from NEUTRAL at 800 ± 25 rpm.
High Idle Checks and Parasitic Loss Test
- Adjust the input rotation to 800 ± 25 rpm in the NEUTRAL position.
- Shift the transmission to REVERSE.
- Adjust the input rotation to 1900 ± 25 rpm.
- Record the values in Table 15 and Table 17.
- Verify that the power loss does not exceed the value in Table 14.
- Verify all test points with the values in Table 14 and Table 16.
- Adjust the input rotation to 800 ± 25 rpm.
- Shift the transmission to NEUTRAL.
- Shift the transmission to FORWARD 1.
- Adjust the input rotation to 1900 ± 25 rpm.
- Record the values in Table 15 and Table 17.
- Verify that the power loss does not exceed the value in Table 14.
- Verify all test points with the values in Table 14 and Table 16.
- Adjust the input rotation to 800 ± 25 rpm.
- 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.
Note: Make all shifts from NEUTRAL at 800 ± 25 rpm.
Pump Flow Check
- Adjust the input rotation to 800 ± 25 rpm in NEUTRAL.
- Shift the transmission to FORWARD 2.
- Increase the input rotation until the cooler flow is equal to
95 ± 31 L/min (25 ± 8 US gpm) . - The lubrication pressure must be
159 ± 28 kPa (23 ± 4 psi) . - The input rotation must be between 1950 ± 100 rpm.
- Record the values in Table 18.
- Adjust the input rotation to 800 ± 25 rpm.
- Shift the transmission through FORWARD 1 to the NEUTRAL position.
Latching Test
- Adjust the input rotation to 800 ± 25 rpm in NEUTRAL.
- Shift the transmission to FORWARD 1.
- Press the "8" key to turn off the transmission harness. This function will simulate a harness failure.
- 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.
- 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.
- Shift the transmission to the next gear range.
- Verify that the active clutches are correct for each gear range. Refer to Table 5.
- Repeat Steps 3 through 7 until all forward gear ranges are tested and recorded.
Note: Perform this test if your transmission arrangement is equipped with a latching system.
Transmission Clutch Assignments | ||||||
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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
- Stop the input rotation.
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Illustration 44 g00918765 Tooling (N) Show/hide tableIllustration 45 g00918767 ( 25) Engine Output Speed Sensor
(26) Torque Converter Output Speed Sensor
(27) Transmission Output Speed Sensor "A"
(28) Transmission Output Speed Sensor "B" - Use Tooling (N) to measure the resistance of each speed sensor. Measure speed sensors (25), (26), (27), and (28).
- Record the values in Table 20.
- Verify all test points with the values in Table 20.
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.
Contamination Control
- Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.
- Record the results in Table 21.
- Remove the transmission from the test bench if the test bench oil supply is within specifications.
Transmission Bench Test Data Sheet
AVSpare | Transmission Bench Test Data Sheet | Test Date:_______ |
Model:_______ | ||
Work Order:_______ | Serial No.:_______ |
Solenoid Test
Measured Resistance (Ω at |
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Solenoid | Description | Measured Resistance |
1 | Clutch 1 | 9 Ω ± 1 Ω |
2 | Clutch 2 | 9 Ω ± 1 Ω |
3 | Clutch 3 | 9 Ω ± 1 Ω |
4 | Clutch 4 | 9 Ω ± 1 Ω |
5 | Clutch 5 | 9 Ω ± 1 Ω |
6 | Clutch 6 | 9 Ω ± 1 Ω |
7 | Lockup Clutch | 9 Ω ± 1 Ω |
8 | Latching | 33 Ω ± 1 Ω |
Solenoid Test | Measured Resistance (Ω at |
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1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | |
_____ohms |
_____ohms | _____ohms | _____ohms | _____ohms | _____ohms | _____ohms | _____ohms |
Start Checks
Lubrication Pressure | Input Speed (800 ± 25 rpm)
Lubrication Pressure |
_______kPa _______(psi) |
Low Idle Checks
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 | |||||||||||||
N | |
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R | |
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179 ± 20 rpm | |||||||||
F1 | |
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140 ± 10 rpm | |||||||||
F2 | |
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224 ± 10 rpm | |||||||||
F3 | |
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294 ± 10 rpm | |||||||||
F4 | |
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411 ± 10 rpm | |||||||||
F5 | |
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560 ± 10 rpm | |||||||||
F6 | |
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800 ± 10 rpm | |||||||||
F7 | |
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1088 ± 10 rpm | |||||||||
F8 | |
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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. |
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 |
N | ________ |
________ | ________ | ________ | ________ | ________ | ________ | |
R | ________ |
________ | ________ | ________ | ________ | ________ | ________ | |
F1 | ________ |
________ | ________ | ________ | ________ | ________ | ________ | ________ |
F2 | ________ |
________ | ________ | ________ | ________ | ________ | ________ | ________ |
F3 | ________ |
________ | ________ | ________ | ________ | ________ | ________ | ________ |
F4 | ________ |
________ | ________ | ________ | ________ | ________ | ________ | ________ |
F5 | ________ |
________ | ________ | ________ | ________ | ________ | ________ | ________ |
F6 | ________ |
________ | ________ | ________ | ________ | ________ | ________ | ________ |
F7 | ________ |
________ | ________ | ________ | ________ | ________ | ________ | ________ |
F8 | ________ |
________ | ________ | ________ | ________ | ________ | ________ | ________ |
(1) | Supply Pressure |
Clutch Pressures | ||||||||||||
Gear | Clutch 1 | Clutch 2 | Clutch 3 | Clutch 4 | Clutch 5 | Clutch 6 | ||||||
N | |
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R | |
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F8 | |
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Clutch Pressures | |||||||
Gear | Clutch 1 | Clutch 2 | Clutch 3 | Clutch 4 | Clutch 5 | Clutch 6 | |
N | ___________ |
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R | ___________ |
___________ |
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F1 | ___________ |
___________ |
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F2 | ___________ |
___________ |
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F3 | ___________ |
___________ |
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F4 | ___________ |
___________ |
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F5 | ___________ |
___________ |
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F6 | ___________ |
___________ |
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F7 | ___________ |
___________ |
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F8 | ___________ |
___________ |
High Idle Pressure Checks
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 | |||||||||||||
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(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. |
High Idle Checks | Input Speed (1900 ± 25 rpm)
Downshifts (1450 ± 25 rpm) |
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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) |
N | ________ |
________ | ________ | ________ | ________ | ________ | ________ | |
R | ________ |
________ | ________ | ________ | ________ | ________ | ________ | |
F1 | ________ |
________ | ________ | ________ | ________ | ________ | ________ | ________ |
F2 | ________ |
________ | ________ | ________ | ________ | ________ | ________ | ________ |
F3 | ________ |
________ | ________ | ________ | ________ | ________ | ________ | ________ |
F4 | ________ |
________ | ________ | ________ | ________ | ________ | ________ | ________ |
F5 | ________ |
________ | ________ | ________ | ________ | ________ | ________ | ________ |
F6 | ________ |
________ | ________ | ________ | ________ | ________ | ________ | ________ |
F7 | ________ |
________ | ________ | ________ | ________ | ________ | ________ | ________ |
F8 | ________ |
________ | ________ | ________ | ________ | ________ | ________ | ________ |
(1) | Supply Pressure |
Clutch Pressures | ||||||||||||
Gear | Clutch 1 | Clutch 2 | Clutch 3 | Clutch 4 | Clutch 5 | Clutch 6 | ||||||
N | |
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R | |
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F1 | |
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F2 | |
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F3 | |
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F4 | |
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F5 | |
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F6 | |
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F7 | |
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F8 | |
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Clutch Pressures | |||||||
Gear | Clutch 1 | Clutch 2 | Clutch 3 | Clutch 4 | Clutch 5 | Clutch 6 | |
N | ___________ |
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R | ___________ |
___________ |
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F1 | ___________ |
___________ |
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F2 | ___________ |
___________ |
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F3 | ___________ |
___________ |
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F4 | ___________ |
___________ |
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F5 | ___________ |
___________ |
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F6 | ___________ |
___________ |
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F7 | ___________ |
___________ |
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F8 | ___________ |
___________ |
Pump Flow Check
Pump Flow Check | Input Speed (800 ± 25 rpm) | ||
Lubrication Pressure | Input Speed | ||
_______kPa (psi) |
_______ rpm |
Speed Sensor Test
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 |
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
Contamination Control | Sample the test bench oil supply. *ISO 4406 is 16/13 or better |
________/________Particle Count |
______________________________________ Technician |
______________________________________ Supervisor |