Bench Test Procedure for a 793C Off-Highway Truck Transmission{3030, 3073} Caterpillar

Off-Highway Truck/Tractor:

793C (S/N: 4AR1-UP; ATY1-UP; 4GZ1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS1344
06	Improved Installation Procedure. Standardized.
05	Updated Table 14 and Table 19.
04	Added new Introduction and Canceled Parts Number section.

© 2015 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This special instruction contains the necessary information that is required to bench 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 Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This guideline must be used with the latest technical information that is available from Caterpillar.

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

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

• Knowledge Network

Table 2

Machine Model	Transmission Arrangement
793C	9U-9822

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 in order to perform maintenance, repair, or operate any machine. Safety precautions and warnings are provided this instruction and on Caterpillar products. These warnings should be observed before performing any procedures. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are not all inclusive.

The hazards are identified by the "Safety Alert Symbol" which is followed by a "Signal Word" such as "DANGER", "WARNING" or "CAUTION". The "WARNING" Safety Alert Symbol is shown in illustration below.

Illustration 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.

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

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

Collecting the Test Data

Since conditions vary for each test bench, it is important to 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.

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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

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9584	Rail As	1
	1U-9585	Mounting Block Gp	1
	1U-9586 (4)	Swivel Head Support Gp	1
B	1U-8847	Adapter Plate	1
	2H-3740	Bolt (3/4-16X1.25 inch)	4
C	1U-9131	Drive Adapter (Key) (1)	1
D	1U-9359	Drive Adapter (2)	1
E	1U-5935	Plate As	1
	0L-1178	Bolt (3/4-10X2.0 inch)	2
	5P-8248	Hard Washer	2
	2J-3506	Full Nut	2
	1B-4367	Bolt (5/8-11X3.5 inch)	2
	4B-5275	Washer	2
	1D-4720	Nut	2
	5D-6428	O-Ring Seal	1
F	1U-9722	Load Binder As	4
	138-7573	Link Bracket	2
G	1U-5999	Spindle Gp	1
	8B-7997	Bolt (1/2-13X2.0 inch)	4
H	1U-8654	Adapter (Splined)	1
J	5T-7967	Adapter	1
	5F-8807	Bolt (1/2-13X1.25 inch)	4
K	1U-8301	Fitting	1
	9U-7445	Adapter	1
	1P-4578	Half Flange	2
	8C-9024	Fitting As (Plain)	1
	6V-3965	Fitting As (Quick Disconnect)	1
	3J-1907	O-Ring Seal	1
	0T-0319	Bolt (7/16-14X2.0 inch)	4
L	9U-7446	Adapter	1
	1U-8304	Fitting	1
	6V-3965	Fitting As (Quick Disconnect)	1
	8C-9024	Fitting As (Plain)	1
	1P-4579	Half Flange	2
	9S-1366	Bolt (1/2-13X1.25 inch)	4
	3J-1907	O-Ring Seal	1
M	9U-7446	Adapter	1
	1U-8301	Fitting	1
	6V-3965	Fitting As (Quick Disconnect)	1
	8C-9024	Fitting As (Plain)	1
	1P-4579	Half Flange	2
	9S-1366	Bolt (1/2-13X1.25 inch)	4
	3J-1907	O-Ring Seal	1
N	6V-3965	Fitting As	1
	3J-1907	O-Ring Seal	1
P	3B-6552	Elbow	1
	3B-7282	Pipe Nipple	1
	6V-4142	Fitting (Test)	1
Q	4C-4898	Cover (Transmission Test) (3)	1
R	9U-7500	Transmission Analyzer Tool Gp	1
	OR
	277-2362	Transmission Analyzer III Gp	1
	306-0397	Adapter Cable As (Transmission Analyzer)	1
	1U-9482	Adapter Cable As	1
	4C-5974	Cable Adapter	1
S	8T-0855	Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))	10
	6V-4144	Coupler	10
T	8T-0853	Pressure Gauge (0 to 400 kPa (0 to 58 psi))	1
	6V-4144	Coupler	1

( 4 )	Refer to Illustration 3.
( 1 )	This drive adapter is used with the small drive shaft.
( 2 )	This drive adapter is used with the large drive shaft.
( 3 )	FT-1874 can be used.

Illustration 3	g00899364

Optional Tools

Illustration 4	g00899365

Table 4

Required Tools
Tool	Part Number	Part Description	Qty
U	131-5050	Dataview Tool Gp (1)	1
	143-4065	Pressure Sensor (0 to 6900 kPa (0 to 1000 psi))	5
	6V-2198	Cable	5

( 1 )

The compatible computer system is not included.

Installation Procedure

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Illustration 5	g03862132

1. Install Tooling (A) to test bench.

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Illustration 6	g00913598

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

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Illustration 7	g00913599

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

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Illustration 8	g00913600

4. Install Tooling (C) onto 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 (B) .

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Illustration 9	g00913601

5. Align the transmission with the input drive shaft.

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

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Illustration 10	g00913602

7. Close and latch drive shaft guard.

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Illustration 11	g03802221

8. Tighten all four castle nuts and jack bolts.

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Illustration 12	g00913603

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

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Illustration 13	g03862641

10. Install two bolts in the bottom locations, as shown.

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Illustration 14	g00913605

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Illustration 15	g00913606

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

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Illustration 16	g00913607

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

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Illustration 17	g00913608

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.

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

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Illustration 18	g00913609

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

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

16. 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).

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

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

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Illustration 19	g00913615

18. Loosen bolt (1) .

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Illustration 20	g00913616

19. 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.

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

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

21. Tighten bolt (1) .

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Illustration 21	g03862267

22. Install Tooling (J) .

23. Install Tooling (K) to Tooling (J) .

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Illustration 22	g03862272

24. Install Tooling (L) .

25. Install Tooling (M) .

26. Install Tooling (N) .

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Illustration 23	g00913659

27. Remove bracket (3) .

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Illustration 24	g00913660

28. Remove cover (4) .

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Illustration 25	g03862782

29. Install Tooling (P) .

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Illustration 26	g03862783

30. Install Tooling (Q) .

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Illustration 27	g00899389

31. The transmission magnetic screen has been removed to allow the oil to drain during testing.

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Illustration 28	g03862798

32. Remove drain plug (5)

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Illustration 29	g03862913
Supply Oil

33. Connect hose assembly (6) from the pressurized flow meter to Tooling (L) .

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Illustration 30	g03862920

34. Connect hose assembly (7) from Tooling (M) to the No. 2 flow meter inlet.

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Illustration 31	g03862930
Lube (in)

35. Connect hose assembly (8) from the No. 2 flow meter outlet to Tooling (K) .

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Illustration 32	g03862933

36. Connect lube line (9) from the test bench to Tooling (G). Maintain an oil pressure of 276 kPa (40 psi).

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Illustration 33	g03862938
(10) Lockup Clutch Pressure

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

37. Connect pressure gauge (10) to Tooling (N) .

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Illustration 34	g03862287
(11) Lubrication Pressure

38. Connect pressure gauge (11) to Tooling (K) .

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Illustration 35	g03862941
(12) Pilot Oil Pressure

39. Connect pressure gauge (12) to Tooling (P) .

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Illustration 36	g03862949
(13) Pressure tap for the transmission charge pump (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 signal pressure of the dual stage relief valve in the selector and pressure control (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

40. Connect eight pressure gauges to pressure taps (13), (14), (15), (16), (17), (18), (19), and (20) .

    Note: Pressure tap "H" is not used.

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Illustration 37	g03862950
(21) Upshift Solenoid (22) Downshift Solenoid (23) Lockup Clutch Solenoid

41. Connect Tooling (P) to solenoids (21), (22), and (23) .

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Illustration 38	g03862954

42. Connect Tooling (R) to harness connector (24) and a suitable location.

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Illustration 39	g00877510
Tooling (R)

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Illustration 40	g01457869
Tooling (R)

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

Test Procedure

TA3 Navigation

1. Select "Off-Highway Trucks".

2. Select "793C - 24V".

Harness Test (TA3 Only)

1. Make sure that the harness is properly connected.

2. Use Tooling (R) to perform the harness test.

3. Record the values in Table 7.

   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 (R) to perform the solenoid test.

3. Record the values in Table 7.

   Note: Do not continue testing until Solenoid Test passes.

Start Checks

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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.

Note: Refer to Testing and Adjusting, SENR1450, "793C 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.

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

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Illustration 41	g02720621

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

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

5. Confirm the correct clutch engagement with Table 5.
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   Table 5

   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

6. Check for lockup or excessive drag in all ranges.

7. Adjust the input rotation to 0 rpm.

8. Use the following procedure to test the transmission.

Transmission Charging Pump Pressure (Torque Converter Drive)

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

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

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

4. Adjust the dual stage relief valve until the pressure that is measured at the port for the transmission charge pump is greater than 2515 kPa (365 psi).

5. Adjust the input flow to 148 ± 4 L/min (40 ± 1 US gpm).

6. Adjust the input rotation to 1750 ± 30 rpm.

7. Check the pressure for the dual stage relief valve. The pressure must not exceed 3065 kPa (445 psi).

8. Record the value in Table 8.

9. Shift the transmission to the NEUTRAL 2 position.

Supply Pressure

1. Adjust the input flow to 110 ± 4 L/min (30 ± 1 US gpm).

2. Adjust the input rotation to 1300 ± 30 rpm.

3. Energize the lockup clutch solenoid.

4. Check the pressure for the clutch supply rail. The correct pressure is 1620 ± 70 kPa (235 ± 10 psi).

5. Record the value in Table 9.

Transmission Charging Pump Pressure (Direct Drive)

1. Adjust the input flow to 110 ± 4 L/min (30 ± 1 US gpm).

2. Adjust the input rotation to 1300 ± 30 rpm.

3. Energize the lockup clutch solenoid.

4. Shift the transmission to the NEUTRAL 1 position.

5. Check the pressure at the port for the charge pump. The correct pressure is 2310 ± 70 kPa (335 ± 10 psi).

6. If necessary, adjust the priority reducing valve. The correct pressure setting is 2310 ± 70 kPa (335 ± 10 psi).

7. Record the value in Table 10.

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 to the transmission.

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

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

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

5. Record the values in Table 11.

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

7. Record the value in Table 12.

Lube Circuit Check

1. Shift the transmission to FORWARD 2.

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

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

4. The lubrication pressure must be within 7 kPa (1 psi) of the average for this arrangement. Reference is 51.7 ± 10.3 kPa (7.5 ± 1.5 psi).

5. Record the value in Table 13.

6. Stop the input rotation.

7. Stop the input flow.

Primary Clutch Pressure Checks

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Illustration 42	g00899421

1. Remove Tooling (H) .

2. Remove the load piston plugs (19) from selector valve "A", "B", "C", "E", "F", and "G".

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

3. Install Tooling (H) .

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

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

6. The lockup solenoid must be de-energized.

7. Shift the transmission through each gear range.

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

9. Verify that the primary clutch pressures match the values in Table 14.

Final Pressure Checks (Low Idle)

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

2. Install Tooling (H) .

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

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

5. 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.

6. Record the clutch pressure for each gear range in Table 17.

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

Final Pressure Checks (High Idle)

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

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

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

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

5. Record the clutch pressure in Table 19.

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

7. 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.

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

9. Energize the lockup clutch solenoid.

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

11. Record the clutch pressure in Table 19.

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

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

14. Verify that the clutch pressures match the values in Table 18.

Transmission Bench Test Data Sheet

Table 6

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

Solenoid Test

Table 7

Solenoid Test	Solenoid 1	Solenoid 2	Solenoid 3
	_______ ohms	_______ ohms	_______ ohms

Transmission Charging Pump Pressure (Torque Converter Drive)

Table 8

Transmission Charging Pump Pressure (Torque Converter Drive)	Input Speed (700 ± 30 rpm) Input Flow 57 ± 4 L/min (15 ± 1 US gpm) MIN 2515 kPa (365 psi)			_______kPa _______(psi)
	Input Speed (1750 ± 30 rpm) Input Flow 148 ± 4 L/min (39 ± 1 US gpm) MAX 3065 kPa (445 psi)			_______kPa _______(psi)

Supply Pressure

Table 9

Supply Pressure

Input Speed (1300 ± 30 rpm) Input Flow 110 ± 4 L/min (29 ± 1 US gpm)

_______kPa _______(psi)

Transmission Charging Pump Pressure (Direct Drive)

Table 10

Transmission Charging Pump Pressure (Direct Drive)

Input Speed (1300 ± 30 rpm) Input Flow 110 ± 4 L/min (29 ± 1 US gpm)

_______kPa _______(psi)

Neutralizer Valve

Table 11

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 12

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 13

Lube Circuit Check		Gear Range FORWARD 2 Input Speed (700 ± 30 rpm) Lube Flow 57 ± 4 L/min (15 ± 1 US gpm)
Average Lubrication Pressure Of Arrangement	_______kPa _______(psi)	Lubrication Pressure	_______kPa _______(psi)

Primary Pressure Checks

Table 14

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)
N1	3	0	0	480 kPa (70 psi)	0	0	0
N2	1	0	475 kPa (69 psi)	0	0	0	0
R	1 and 6	0	475 kPa (69 psi)	0	0	0	425 kPa (62 psi)
F1	1 and 5	0	475 kPa (69 psi)	0	0	450 kPa (65 psi)	0
F2	2 and 5	525 kPa (76 psi)	0	0	0	450 kPa (65 psi)	0
F3	1 and 4	0	475 kPa (69 psi)	0	425 kPa (62 psi)	0	0
F4	2 and 4	525 kPa (76 psi)	0	0	425 kPa (62 psi)	0	0
F5	1 and 3	0	475 kPa (69 psi)	480 kPa (70 psi)	0	0	0
F6	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 15

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).

Final Pressure Checks (Low Idle)

Table 16

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)
N2	1	0	2400 kPa (348 psi)	0	0	0	0
R	1 and 6	0	2400 kPa (348 psi)	0	0	0	2585 kPa (375 psi)
F1	1 and 5	0	2400 kPa (348 psi)	0	0	2585 kPa (375 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 17

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
N2	1
R	1 and 6
F1	1 and 5

Final Pressure Checks (High Idle)

Table 18

Clutch Pressure In Direct Drive 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
Speed Position	Engaged Clutches	Pressure (3)	Pressure (3)	Pressure (3)	Pressure (3)	Pressure (3)	Pressure (3)
F2	2 and 5	1620 kPa (235 psi)	0	0	0	1620 kPa (235 psi)	0
F3	1 and 4	0	1620 kPa (235 psi)	0	1620 kPa (235 psi)	0	0
F4	2 and 4	1620 kPa (235 psi)	0	0	1620 kPa (235 psi)	0	0
F5	1 and 3	0	1620 kPa (235 psi)	1620 kPa (235 psi)	0	0	0
F6	2 and 3	1620 kPa (235 psi)	0	1620 kPa (235 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 19

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
N1	3
N2	1
R	1 and 6
F1	1 and 5
Direct Drive
F2	2 and 5
F3	1 and 4
F4	2 and 4
F5	1 and 3
F6	2 and 3

ISO Particle Count

Table 20

ISO Particle Count

Sample the test bench oil supply.

________/________Particle Count

Table 21

______________________________________ Technician

______________________________________ Supervisor

Shift Traces

Introduction

Shift traces have become an important tool for validating the proper operation and assembly of the component. The shift cycles are recorded and reviewed in order to analyze the specific segments of the shift cycle. The segments are decay times, fill times, and modulation times. Shift traces can reveal faulty parts or omitted parts. Shift traces can alert the technician to potential problems.

Correct interpretation of terminology is essential for understanding shift traces. Refer to Illustration 44 and Illustration 45 in order to interpret your shift traces correctly.

Collecting the Test Data

Since conditions vary for each test bench, it is important to 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.

These averages should be entered on the worksheets. A shift trace is included on each worksheet.

Note: Refer to Table 4 for the required tooling.

Show/hide table



Illustration 43	g00899422

1. Install Tooling (U) on pressure taps, "A", "B", "C", "E", and "F".

Illustration 44	g00899108

Illustration 45	g00899331

Shift Trace (2F-3F)

Table 22

Shift Trace Graph Definition
Selected Channels	2A, 1B, 4E, 5F
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	900 rpm

Table 23

Channel Assignments
Data Channel		2A	1B	4E	5F
Clutch No.		1	2	4	5
Sampling Rate		100 per sec

Illustration 46	g00899423

Table 24

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	2	.200 sec ± 15%	_____________ sec	_____________ sec
Decay Time	5	.250 sec ± 15%	_____________ sec	_____________ sec
Fill Time	1	.390 sec ± 15%	_____________ sec	_____________ sec
Fill Time	4	.360 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	1	.320 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	4	.270 sec ± 15%	_____________ sec	_____________ sec

Shift Trace (3F-4F)

Table 25

Shift Trace Graph Definition
Selected Channels	2A, 1B, 4E
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	900 rpm

Table 26

Channel Assignments
Data Channel		2A	1B	4E
Clutch No.		1	2	4
Sampling Rate		100 per sec

Illustration 47	g00899425

Table 27

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	1	.130 sec ± 15%	_____________ sec	_____________ sec
Fill Time	2	.400 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	2	.240 sec ± 15%	_____________ sec	_____________ sec

Shift Trace (4F-5F)

Table 28

Shift Trace Graph Definition
Selected Channels	2A, 1B, 3C, 4E
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	900 rpm

Table 29

Channel Assignments
Data Channel		2A	1B	3C	4E
Clutch No.		1	2	3	4
Sampling Rate		100 per sec

Illustration 48	g00899426

Table 30

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	2	.200 sec ± 15%	_____________ sec	_____________ sec
Decay Time	4	.120 sec ± 15%	_____________ sec	_____________ sec
Fill Time	1	.370 sec ± 15%	_____________ sec	_____________ sec
Fill Time	3	.240 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	1	.320 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	3	.240 sec ± 15%	_____________ sec	_____________ sec

Shift Trace (5F-6F)

Table 31

Shift Trace Graph Definition
Selected Channels	2A, 1B, 3C
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	900 rpm

Table 32

Channel Assignments
Data Channel		2A	1B	3C
Clutch No.		1	2	3
Sampling Rate		100 per sec

Illustration 49	g00899429

Table 33

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	1	.130 sec ± 15%	_____________ sec	_____________ sec
Fill Time	2	.390 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	2	.230 sec ± 15%	_____________ sec	_____________ sec

Shift Trace (3F-2F)

Table 34

Shift Trace Graph Definition
Selected Channels	2A, 1B, 4E, 5F
Maximum Pressure	3445 kPa (500 psi)
Input Shaft Speed	900 rpm

Table 35

Channel Assignments
Data Channel		2A	1B	4E	5F
Clutch No.		1	2	4	5
Sampling Rate		100 per sec

Illustration 50	g00899430

Table 36

Shift Trace Analysis Worksheet
Description	Clutch	Target	Test Bench Data History	Actual
Decay Time	1	.130 sec ± 15%	_____________ sec	_____________ sec
Decay Time	4	.120 sec ± 15%	_____________ sec	_____________ sec
Fill Time	2	.370 sec ± 15%	_____________ sec	_____________ sec
Fill Time	5	.370 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	2	.220 sec ± 15%	_____________ sec	_____________ sec
Modulation Time	5	.440 sec ± 15%	_____________ sec	_____________ sec