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

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 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

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 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.

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.

Table 3

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

(1)	Pomona Model 1330-0

Installation Procedure

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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.

1. Assemble Tooling (A).
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   Illustration 4	g00915751

2. Install Tooling (A) to the output end of the transmission.
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   Illustration 5	g00915752

3. Use a hoist to install the transmission on the test bench. The weight of the transmission is 950 kg (2094 lb).
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   Illustration 6	g00915754

4. Install Tooling (A) to the input end of the transmission.
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   Illustration 7	g00915755

5. Install Tooling (A) to the output end of the transmission.
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   Illustration 8	g00915756

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

7. Install Tooling (B) to the torque converter.
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   Illustration 9	g00915758

8. 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.

9. Install Tooling (D) on Tooling (C).
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   Illustration 11	g00915764

10. Tighten the collet on Tooling (D) to connect Tooling (D) to Tooling (B).
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    Illustration 12	g00915766

11. Install Tooling (E) to the input shaft of Tooling (D).
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    Illustration 13	g00915768

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).

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    Illustration 14	g00915772

13. Align the transmission with the input drive shaft.

14. Connect the input drive shaft to Tooling (F).
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    Illustration 15	g00915774

15. Install the drive shaft guard.
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    Illustration 16	g03802221

16. Tighten all four castle nuts and jack bolts.
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    Illustration 17	g00878734
    Input end of transmission

17. Install Tooling (H) to the input end of the transmission.
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    Illustration 18	g00915777
    Output end of transmission

18. Install Tooling (H) to the output end of the transmission.
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    Illustration 19	g06000482

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.

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    Illustration 20	g00915783

21. Install Tooling (J).
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    Illustration 21	g00915787

22. Connect hose assembly (1) from the pump supply to Tooling (P).
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    Illustration 22	g00915790

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.

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    Illustration 23	g00915791

24. Connect hose assembly (3) from the No. 2 flow meter outlet to Tooling (J).
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    Illustration 24	g00915793

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

26. Connect Tooling (K) to six clutch solenoids.
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    Illustration 26	g00878743
    Cable connector (7-G) for lockup clutch solenoid (11)

27. 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.

28. Connect Tooling (K) to latching solenoid (12).
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    Illustration 28	g00878745
    Tooling (K)

29. Connect Tooling (K) to a suitable location.
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    Illustration 29	g00878746
    (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).
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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

32. 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

33. Connect a pressure gauge to pressure tap (21).
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    Illustration 32	g00915825
    (22) Latching Rail Pressure

34. Connect a pressure gauge to pressure tap (22).
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    Illustration 33	g00915828
    (23) Torque Converter Outlet Pressure

35. Connect a pressure gauge to pressure tap (23).
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    Illustration 34	g00915831
    (24) Lubrication Pressure

36. Connect a pressure gauge to pressure tap (24).
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    Illustration 35	g00915833
    Tooling (M)

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    Illustration 36	g06003033
    Tooling (M)

37. Install Tooling (M) on the output yoke.
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    Illustration 37	g00877510
    Tooling (K)

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    Illustration 38	g01457869
    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 39	g00878491

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 40	g00878493

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

Illustration 41	g00878495

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

Illustration 42	g00915664

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.
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   Illustration 43	g02720621

   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
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

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.
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   Illustration 44	g00918765
   Tooling (N)

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   Illustration 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"

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

AVSpare	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
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

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

N

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)

R

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
N	________	________	________	________		________	________	________
R	________	________	________	________		________	________	________
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
N											2344 ± 138 kPa (340 ± 20 psi)
R					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
N							___________
R				___________			___________
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

N

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)

R

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)

1

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)

2

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)

3

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)

4

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)

5

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)

6

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)

7

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)

8

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)
N	________	________	________	________		________	________	________
R	________	________	________	________		________	________	________
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
N											2344 ± 138 kPa (340 ± 20 psi)
R					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
N							___________
R				___________			___________
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