Bench Test Procedure for 966K XE Wheel Loader Transmission {3030, 3073} Caterpillar

Bench Test Procedure for 966K XE Wheel Loader Transmission {3030, 3073}

Usage:

Wheel Loader: 966K Series XE (S/N: NGX1-UP)

Introduction

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Table 1
Revision	Summary of Changes in M0083841
01	Updated Table 3. Updated Multiple Graphics. Added Several Notes to Set up Procedure and to Tables.
00	New Document.

© 2018 Caterpillar All Rights Reserved. This document 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.

This document contains the necessary information that is required to bench test- specific transmission arrangements. 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 document are specific to bench testing the component. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This document must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

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Table 2
Machine Model	Transmission Arrangement
966K XE	345-3360

Canceled Part Numbers and Replaced Part Numbers

This document may not 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 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.

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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.

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

Collecting the Test Data

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

Data from each transmission arrangement is collected and stored. Averages from each transmission arrangement are often used to compare values on portions of transmission tests. 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 extra filtering can affect pressure. The required tools that are listed in Table 3 were used to develop this test procedure. Table 3 is a suggested list. Parts may vary depending on availability and bench configuration.

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Table 3
Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9584	Rail As	2
	4C-9998	Bracket As	2
	356-3011	Crossmember	1
	369-5916	Lifting Eye	1
	7X-0373	Bolt	4
	6V-8182	Nut	4
	5P-8248	Hard Washer	8
B	136-3648	Drive Adapter As	1
C	1U-9131	Drive Adapter	1
D	1U-6698	Adapter As	1
	2J-5245	Bolt (3/8-16X1.25-IN)	4
	3B-4508	Lockwasher	4
E	1U-9722	Load Binder As	2
E	395-1098	Lifting Eye Assembly	4
F	362-0698	Sight Gauge	1
G	6V-3965	Nipple Q Disc	8
	3J-1907	O-Ring Seal	12
	085-7356⁽¹⁾	Fitting	4
	6V-8076⁽¹⁾	Elbow	4
H	558-4566	3 inch Female Cam Lock	1
	287-7338	Reducer Bushing	1
	141-2502	Reducer Bushing	1
	1L-4031⁽²⁾	Tee	1
	8C-9024	Nipple Q Disc	4
	8C-9025	Quick Coupler	2
	005-8615	Pipe Nipple	2
	120-6843	Ball Valve	2
J	8C-9033	Coupler Q Disc	1
	5P-0492	Adapter	1
	7M-8485	O-Ring Seal	1
	005-8615	Pipe Nipple	1
	4B-7770	Tee	1
	8C-9024	Fitting As	2
K	6V-7483	Adapter	1
	3D-2824	O-Ring Seal	1
	004-5703	Pipe Adapter	1
	005-8615	Pipe Nipple	1
	120-6843	Ball Valve	1
	3B-6555	Elbow	1
L	9X-2101	Elbow	1
	7M-8485	O-Ring Seal	1
	8C-9024	Fitting As	1
M	448-9011⁽³⁾	Tee Adapter	1
	9T-5212	Adapter	1
	6V-8076	Elbow	1
	6V-3965	Fitting	1
	3J-1907	O-Ring Seal	2
	5P-0492	Adapter	1
	7M-8485	O-Ring Seal	3
	8C-9024	Fitting As	1
N	392-6348⁽⁴⁾	Accumulator Gp	2
	6V-5258	Adapter	2
	3D-2824	O-Ring Seal	2
	4I-6140	Coupling	2
	7M-8485	O-Ring Seal	2
	114-8196	Elbow	2
	228-7092	O-Ring Seal	2
Q	5P-0492	Adapter	2
	7M-8485	O-Ring Seal	2
	8C-9024	Fitting As	2
R	1U-9874	Adapter	1
	6J-2680	O-Ring Seal	1
	8T-7811	Bolt	4
	287-7338	Reducer Bushing	1
	141-2502	Reducer Bushing	1
	8C-9024	Fitting As	1
S	7Y-3731	Flange	1
	6V-1820	Bolt	4
	5P-8066	O-Ring Seal	1
	228-7093	O-Ring Seal	1
	8T-4834	O-Ring Face Seal Swivel Tee	1
	5K-9090	O-Ring Seal	1
	6V-3965	Nipple Q Disc	1
	3J-1907	O-Ring Seal	1
	120-6843	Ball Valve	1
	3B-6555	Elbow	1
T⁽⁵⁾	5P-1042	Adapter As	1
	2M-9780	O-Ring Seal	1
	6V-8714	Connector As	1
	3D-2824	O-Ring Seal	1
	5K-9090	O-Ring Seal	1
	124-2155	Coupling As	1
U	540-3111	Adapter Harness	1
		Wiring Harness	1
	306-0397	Extension Cable	1
V	277-2362	Transmission Analyzer Gp	1
W	276-7273	Sensor Test Box	1
X	257-9140	Digital Multimeter	1⁽⁶⁾
Y⁽⁷⁾	6V-7788	Flow Meter Gp (5 TO 60-L/MIN (2 TO 15-US GPM))	1
Z⁽⁷⁾	8T-0454	Flow Meter Gp	2
AA⁽⁷⁾	8T-0855	Pressure Gauge (0 TO 4,000-KPA (0 TO 580-PSI))	11
AA⁽⁷⁾	6V-4144	Quick Connect Coupler	11
BB⁽⁷⁾	8T-0854	Pressure Gauge (0 TO 1,000-KPA (0 TO 144-PSI))	1
BB⁽⁷⁾	6V-4144	Quick Connect Coupler	1
CC⁽⁷⁾	9U-5893	Heat Exchanger	1
	8V-7764	Adapter	2
	6K-6307	O-Ring Seal	1
	5P-0492	Adapter	2
	7M-8485	O-Ring Seal	2
	8C-9024	Fitting As	3
	4B-7770	Pipe Nipple	1

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⁽¹⁾	May be required on some transmissions
⁽²⁾	Can substitute with 4B-7770 and adding another005-8615.
⁽³⁾	This Tee is a tight fight but we are working on getting the Tee that is in the picture released as a Caterpillar part number. When it is release we will add it as the main part number and footnote the current on as an option.
⁽⁴⁾	Optional tooling, needed only if accumulators are not present with the transmission. (Charged to 150psi)
⁽⁵⁾	Use appropriate length 716 -16 hydraulic hose to get to test bed
⁽⁶⁾	Add another multimeter for ease of testing
⁽⁷⁾	Optional Tooling if needed with the test bench

Hydraulic Schematic

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Illustration 3	g06183848

Installation Procedure

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Illustration 4	g06155185

Install Tooling (A) to the test stand.
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Illustration 5 g06155188
Use a hoist to install the transmission onto Tooling (A). The weight of the transmission is 907 kg (2000 lb).
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Illustration 6 g06155189
Install Tooling (B) to the input end of the transmission.
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Illustration 7 g06155444
Install Tooling (C).
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Illustration 8 g06155448
Install Tooling (D).
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Illustration 9 g06155461
Align the transmission with the input drive shaft.
Connect the input drive shaft to Tooling (C).
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Illustration 10 g06155467
Close and latch drive shaft guard.
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Illustration 11 g03375318
Tighten all four castle nuts and jack bolts.
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Illustration 12 g06155475
Install Tooling (E) to both ends of the transmission to prevent movement during the test.
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Illustration 13 g06155476
Install Tooling (F) to maintain oil level during testing.
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Illustration 14 g06155482
Loosen Plug (1) or attach vent line to vent pump load sense to atmosphere. This will keep the pump from up-stroking during the test.
Note: This valve port may weep oil only, but there should be minimal pressure.
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Illustration 15 g06155489
Remove Plugs (2) and (3).
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Illustration 16 g06155496
Install Tooling (G).
Note: Some transmissions may require an 085-7356 Fitting or 6V-8076 Elbow. The manifold may need to be removed to install elbow adapter.
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Illustration 17 g06155510
Remove Plugs (4) and (5).
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Illustration 18 g06155515
Install Tooling (G).
Note: Some transmissions may require an 085-7356 Fitting or 6V-8076 Elbow. The manifold may need to be removed to install elbow adapter.
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Illustration 19 g06155522
Remove Plugs (6-9).
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Illustration 20 g06155552
Install Tooling (G)
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Illustration 21 g06349941
Install Tooling (H) to the Gravity Feed port on the test bench.
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Illustration 22 g06349973
Install Tooling (J) to the Heat Exchanger (out) port on the test bench.
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Illustration 23 g06156805
Remove Plug (10).
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Illustration 24 g06155633
Install Tooling (K).
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Illustration 25 g06156807
Remove Plug (11).
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Illustration 26 g06155644

Transmission Fill (Main Flow)
Install Tooling (L).
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Illustration 27 g06156810
Remove Hose Assembly (12).
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Illustration 28 g06155651

Lube (in)
Install Tooling (M).
Note: The Tee used in Illustration 28 has not yet been part numbered. The Tee we have listed in the tool list will work but is confined in access. We will change the part number once it becomes available.
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Illustration 29 g06155657
Install Tooling (N).
Note: Accumulators should be charged to 1034 kPa (150 psi).
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Illustration 30 g06156802
Remove Plug (13) and Fitting Assembly (14).
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Illustration 31 g06155663

Left: Gerotor Flow
Right: Charge Flow
Install Tooling (Q).
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Illustration 32 g06155690
Remove Cover (15).
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Illustration 33 g06155680

Steering Pump Supply
Install Tooling (R).
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Illustration 34 g06155667
Remove Plug (16).
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Illustration 35 g06155687

Steering Pump Outlet
Install Tooling (S).
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Illustration 36 g06208183
Remove Plug (17).
Note: K Series port location.
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Illustration 37 g06155689

Steering Pump Case Drain
Install Tooling (T).
Note: Tooling (T) allows the pump case drain to drain to the bench oil return. A small amount of oil draining from this port will indicate that the pump is properly lubricated during the test.
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Illustration 38 g06155693

Steering Pump Outlet

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Illustration 39 g06350013

Steering Pump Outlet
Connect Hose Assembly (18) from Tooling (S) to drain.
Note: Use the ball valve to maintain a manageable oil drainage.
Note: Having hose assembly (18) located near the gravity feed ball valves will allow control from one central location.
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Illustration 40 g06155695

Steering Pump Case Drain
Connect Hose Assembly (19) from Tooling (T) to drain.
Note: Be sure to fill the case drain prior to hooking up hose assembly (19).
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Illustration 41 g06350023

Gravity Feed for Transmission Fill

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Illustration 42 g06187188

Transmission Fill
Connect Hose Assembly (20) from Tooling (H) to Tooling (L)
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Illustration 43 g06350024

Gravity Feed for Steering Pump Fill

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Illustration 44 g06187194

Steering Pump Supply
Connect Hose Assembly (21) from Tooling (H) to Tooling (R).
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Illustration 45 g06183957

19 - 190 L/min (5 - 50 US gpm)
Gerotor (out)
Connect Hose Assembly (22) from Tooling (Q) to Flowmeter 1 (in).
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Illustration 46 g06350242
Connect Hose Assembly (23) from Flowmeter 1 (out) to Heat Exchanger (in) on the test bench.
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Illustration 47 g06350309

Heat Exchanger (out)
Connect Hose Assembly (24) from Tooling (J) to Flowmeter 2 (in).
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Illustration 48 g06350327

Heat Exchanger (out)
Connect Hose Assembly (25) from Flowmeter 3 (in) to Tooling (J).
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Illustration 49 g06183962

5 - 57 L/min (2 - 15 US gpm)
Charge Flow (in)
Connect Hose Assembly (26) from Flowmeter 2 (out) to Tooling (Q).
Note: Tooling (Y) shown in Illustration 49 in place of Flowmeter 2 (out).
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Illustration 50 g06156143

19 - 190 L/min (5 - 50 US gpm)
Lube (in)
Connect Hose Assembly (27) from Flowmeter 3 (out) to Tooling (M).
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Illustration 51 g06156147

(28) LoR Pressure (Low Reverse)
(29) HiF Pressure (High Forward)
Connect Pressure Gauges (28) and (29) to Tooling (G).
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Illustration 52 g06156163

(30) Clutch A Pressure
(31) Aux Synchro Pressure
(32) Clutch B Pressure
Connect Pressure Gauges to Pressure Taps (30), (31), and (32).
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Illustration 53 g06156172

(33) HiR Pressure (High Reverse)
(34) LoF Pressure (Low Forward)
Connect Pressure Gauges (33) and (34) to Tooling (G).
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Illustration 54 g06156181

(35) Lube Pressure
Connect Pressure Gauge (35) to Tooling (M).
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Illustration 55 g06156200

(36) Pump A Pressure
(37) Synchro Mod Pressure
(38) Pump B Pressure
(39) Charge Pressure
Connect Pressure Gauges (36-39) to Tooling (G).
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Illustration 56 g06156218
Install Tooling (U) to the transmission.
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Illustration 57 g06156213
Connect Tooling (U) to a suitable location.
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Illustration 58 g06156220
Connect Tooling (U) to Tooling (V). Refer to the Tool Operating Manual , NEHS0996 for the correct operating instructions.

Test Procedure

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NOTICE

The TA3 program for the XE Transmissions is setup to sequence through the steps of each test from beginning to end. To restart the test at any point, select "N" which will return to neutral position without commanding any solenoids. Failure to follow this step may cause a catastrophic failure.

Note: During the entire test, monitor inlet (transmission sump) oil temperature, especially if the test bench does not have an oil cooler. As temperature increases, the resistance of the temperature sensor decreases. During the test, make sure inlet (transmission sump) oil temperature sensor does not drop below 249 Ohms ( 60° C (140° F)).

TA3 Navigation

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Illustration 59	g06150856

Select "CVT Transmission".

Solenoid Reference

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Illustration 60	g06162064

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Illustration 61	g06162067

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Illustration 62	g06162066

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Table 4
Solenoid Reference Table
TA3 Solenoid Name	Solenoid
Solenoid 1	LoF On/Off Solenoid
Solenoid 2	HiR On/Off Solenoid
Solenoid 3	LoR On/Off Solenoid
Solenoid 4	HiF On/Off Solenoid
Solenoid 5	Pump A
Solenoid 6	Pump B
Solenoid 7	Synchro Mod
Solenoid 8	Aux Synchro
Solenoid 9	Clutch A
Solenoid 10	Clutch B

Note: LoF = Low Forward, LoR = Low Reverse, HiF = High Forward, HiR = High Reverse

Harness Test

The Harness Test for XE Transmissions is to verify that each solenoid is connected properly to the TA3. Reference Table 4 in Solenoid Reference section for proper solenoid connections.

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NOTICE

Solenoids must be wired correctly to avoid transmission damage during the test.

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Illustration 63	g06150900

Select "CVT-1-a-Synchro-Neutral".
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Illustration 64 g06150904
Select "Harness Test".
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Illustration 65 g06150913
Verify that all solenoids pass. Record results in Table 6.
Unplug one solenoid and select "Retest".
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Illustration 66 g06150959

Example of Clutch A solenoid unplugged
The unplugged solenoid should appear red and say "Open".
Plug in the unplugged solenoid and select "Retest".
Repeat Steps 4 through 6 with each solenoid to verify that solenoids are connected correctly.

Sensor Test

The Sensor Test for XE Transmissions is designed to check that sensors are wired correctly and reading properly before the test begins.

Connect Tooling (W) to LoF / HiR Synchro position. Verify values with Table 7.
Connect Tooling (W) to LoR / HiF Synchro position. Verify values with Table 7.
Connect Tooling (W) to Aux Synchro position. Verify values with Table 7.
Connect Tooling (W) to Loop A pressure sensor. Verify values with Table 7.
Connect Tooling (W) to Loop B pressure sensor. Verify values with Table 7.
Connect Tooling (W) to Inlet (Sump) Temp sensor. Verify values with Table 7.
Connect Tooling (W) to Flushing Temp sensor. Verify values with Table 7.
Connect Input Speed Sensor and Planetary Speed Sensor to Tooling (U). Verify values with Table 7.
Connect Output Speed Sensor 1 & 2 to Tooling (U). Verify values with Table 7.

Start Up / Warm Up Test

The purpose of this test is to check specifications on startup and again after the oil has warmed up to 550 Ohms 39° C (102° F) on the transmission inlet temperature sensor.

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Illustration 67	g06162076

Fill the transmission past the Minimum Start Level allowing more oil to fill the test bench lines, meters, and cooler.
Note: If needed, manually fill the pumps and hoses with oil to avoid air in the system.
Stop and check transmission oil level. Refill with fill valve if needed and restart.
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Illustration 68 g02720621
Make sure that the shaft rotation is counterclockwise.
Adjust input speed to 800 rpm.
Adjust Backpressure Valve (case drain ball valve) to restrict flow and de-stroke the steering pump. Allow for a small amount of oil flow from the discharge to cool the pump. Make sure a small amount of oil is leaving the case drain.
Adjust Transmission Sump Oil Valve (H) and Transmission Sump Drain Valve (K) to maintain oil level.
Note: Ensure there is Charge Pressure and Lube Pressure immediately after startup. These pressures indicate that the Gerotor pump and Charge pump are providing oil to the transmission.
Warm the transmission oil until Inlet Oil Temperature reads 550 Ohms ( 39° C (102° F)). To help warm the oil faster, increase input speed to 1600 rpm and block any water supplying the bench cooler.
Note: As transmission oil warms up, the resistance in Ohms will decrease. Therefore cold oil will read greater than 550 Ohms and needs to decrease to 550 Ohms ( 39° C (102° F)).
After the transmission is warmed up, record values in Table 8.
Verify values with Table 8.
Note: If Charge Pressure is out of range, adjust the charge pump compensator to achieve the correct pressure.

Lube Relief Test

The purpose of this test is to check to make sure that the lube relief valve opens and input speed increases and to check that the input speed sensor is working correctly.

Set input speed to 800 rpm.
Adjust Backpressure Valve (case drain ball valve) to restrict flow and de-stroke the steering pump. Allow for a small amount of oil flow from the discharge to cool the pump. Make sure a small amount of oil is leaving the case drain.
Adjust Transmission Sump Oil Valve (H) and Transmission Sump Drain Valve (K) to maintain oil level.
Record speed, pressure, flows, and temperature in Table 9.
Set input speed to 1000, 1200, 1400, 1600, and 1700 rpm and record pressure, flow, and temperature at each speed in Table 9.
Ensure that the pressures and flows are increasing for each increase in input speed.
Verify Lube Pressure tapers off around 193 ± 14 kPa (28 ± 2 psi).

Synchro Test

The Synchro Test will ensure that the transmission can properly supply oil pressure to both sides of the LoF / HiR synchronizer and the LoR / HiF synchronizer. Pressure on both sides of the synchro will neutralize the synchronizer.

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Illustration 69	g06209960
Synchro Duty Cycle Chart

Adjust input speed to 800 rpm.
Adjust Backpressure Valve (case drain ball valve) to restrict flow and de-stroke the steering pump. Allow for a small amount of oil flow from the discharge to cool the pump. Make sure a small amount of oil is leaving the case drain.
Adjust Transmission Sump Oil Valve (H) and Transmission Sump Drain Valve (K) to maintain oil level.
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Illustration 70 g06152267
Select "CVT-1-a-Syncro-Neutral".
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Illustration 71 g06152500
Select "Transmission Test".
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Illustration 72 g06152536
Select "Forward Shift" to shift to "LoF-HiR ON" to energize valves.
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Illustration 73 g06152540
Select "Forward Shift" to shift to "Synchro Mod Pulse".
Use Tooling (W) and (X) to verify LoF / HiR position is in active Neutral position. Record value in Table 10.
Note: If Synchro Position is out of range, do not continue. Select "N" to restart test. If test fails 3 times, inspect for a hydraulic or mechanical problem.
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Illustration 74 g06152551
Select "Forward Shift" to shift to "Ramp up Mod". Record values in Table 10.
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Illustration 75 g06152553
Select "Forward Shift" to shift to "Mod OFF".
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Illustration 76 g06152557
Select "Forward Shift" to shift to "LoF-HiR OFF" to de-energize valves. Record values in Table 10.
Note: Charge Flow delta is "Ramp up Mod" minus "LoF-HiR OFF". If Charge Flow delta is out of range, inspect for an internal hydraulic leak.
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Illustration 77 g06152563
Select "Forward Shift" to shift to "LoR-HiF ON" to energize valves.
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Illustration 78 g06152568
Select "Forward Shift" to shift to "Synchro Mod Pulse".
Use Tooling (W) and (X) to verify LoR / HiF position is in active Neutral position. Record value in Table 10.
Note: If Synchro Position is out of range, do not continue. Select "N" to restart test. If test fails 3 times, inspect for a hydraulic or mechanical problem.
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Illustration 79 g06152578
Select "Forward Shift" to shift to "Ramp up Mod". Record values in Table 10.
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Illustration 80 g06152582
Select "Forward Shift" to shift to "Mod OFF".
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Illustration 81 g06152588
Select "Forward Shift" to shift to "LoR-HiF OFF" to de-energize valves. Record values in Table 10.
Note: Charge Flow delta is "Ramp up Mod" minus "LoR-HiF OFF". If Charge Flow delta is out of range, inspect for an internal hydraulic leak.
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Illustration 82 g06152590
Select "N" to return to Neutral position.

Clutch Test

The purpose of the Clutch Test is to make sure that each clutch can build pressure. The test ensures the synchronizers are neutralized before commanding a clutch.

Adjust input speed to 800 rpm.
Adjust Backpressure Valve (case drain ball valve) to restrict flow and de-stroke the steering pump. Allow for a small amount of oil flow from the discharge to cool the pump. Make sure a small amount of oil is leaving the case drain.
Adjust Transmission Sump Oil Valve (H) and Transmission Sump Drain Valve (K) to maintain oil level.
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Illustration 83 g06152951
Select "CVT-1-b-ClutchAB".
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Illustration 84 g06152955
Select "Transmission Test".
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Illustration 85 g06152965
Select "Forward Shift" to shift to "LoF-HiR ON" to energize valves.
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Illustration 86 g06152975
Select "Forward Shift" to shift to "Synchro Mod Pulse".
Use Tooling (W) and (X) to verify LoF / HiR, LoR / HiF and Aux positions are in active Neutral position. Record values in Table 11.
Note: If Synchro Position is out of range, do not continue. Select "N" to restart test. If test fails 3 times, inspect for a hydraulic or mechanical problem.
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Illustration 87 g06152983
Select "Forward Shift" to shift to "LoF-HiR OFF" to de-energize valves.
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Illustration 88 g06152990
Select "Forward Shift" to shift to "Clutch A ON" to energize Clutch A. Record values in Table 11.
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Illustration 89 g06152994
Select "Forward Shift" to shift to "Clutch A OFF" to de-energize Clutch A. Record values in Table 11.
Note: Charge Flow delta is "Clutch A ON" minus "Clutch A OFF". If Charge Flow delta is out of range, inspect for an internal hydraulic leak.
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Illustration 90 g06153003
Select "Forward Shift" to shift to "Clutch B ON" to energize Clutch B. Record values in Table 11.
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Illustration 91 g06153006
Select "Forward Shift" to shift to "Clutch B OFF" to de-energize Clutch B. Record values in Table 11.
Note: Charge Flow delta is "Clutch B ON" minus "Clutch B OFF". If Charge Flow delta is out of range, inspect for an internal hydraulic leak.
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Illustration 92 g06153009
Select "Forward Shift" to shift to "End".
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Illustration 93 g06153013
Select "N" to return to neutral position.

Variator Test

The Variator Test will stroke the variator pump to full negative displacement and full positive displacement and make sure that intermediate speed responds appropriately at 800 rpm. This test also checks that the Loop Pressure sensors are wired correctly because pressure builds slightly on one side of the hydraulic loop when each of the pump solenoids are energized.

Adjust input speed to 800 rpm.
Adjust Backpressure Valve (case drain ball valve) to restrict flow and de-stroke the steering pump. Allow for a small amount of oil flow from the discharge to cool the pump. Make sure a small amount of oil is leaving the case drain.
Adjust Transmission Sump Oil Valve (H) and Transmission Sump Drain Valve (K) to maintain oil level.
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Illustration 94 g06153120
Select "CVT-1-c-Variator".
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Illustration 95 g06153134
Select "Transmission Test".
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Illustration 96 g06153136
Select "Forward Shift" to shift to "Pump A ON" to energize Pump A. Use Tooling (W) and (X) to record values in Table 12.
Note: Connect Tooling (U) Planetary Speed Sensor to Speed Sensor Input #1 to read the Planetary Speed in Hz through the TA3.
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Illustration 97 g06153138
Select "Forward Shift" to shift to "Pump A OFF" to de-energize Pump A. Use Tooling (W) and (X) to record values in Table 12.
Note: Charge Flow delta is "Pump A ON" minus "Pump A OFF". If Charge Flow is out of range, inspect for an internal hydraulic leak.
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Illustration 98 g06153149
Select "Forward Shift" to shift to "Pump B ON" to energize Pump A. Use Tooling (W) and (X) to record values in Table 12.
Note: Connect Tooling (U) Planetary Speed Sensor to Speed Sensor Input #1 to read the Planetary Speed in Hz through the TA3.
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Illustration 99 g06153167
Select "Forward Shift" to shift to "Pump A OFF" to de-energize Pump A. Use Tooling (W) and (X) to record values in Table 12.
Note: Charge Flow delta is "Pump B ON" minus "Pump B OFF". If Charge Flow is out of range, inspect for an internal hydraulic leak.
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Illustration 100 g06153133
Select "N" to return to neutral position.

Reverse Test

This test will accelerate the transmission through Low Reverse range and end when the HiR synchro engages properly.

Adjust input speed to 800 rpm.
Adjust Backpressure Valve (case drain ball valve) to restrict flow and de-stroke the steering pump. Allow for a small amount of oil flow from the discharge to cool the pump. Make sure a small amount of oil is leaving the case drain.
Adjust Transmission Sump Oil Valve (H) and Transmission Sump Drain Valve (K) to maintain oil level.
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Illustration 101 g06153813
Select "CVT-1-d-Reverse".
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Illustration 102 g06153814
Select "Transmission Test".
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Illustration 103 g06153821
Select "Forward Shift" to shift to "All Syncros ON" to energize all synchro On/Off valves.
Note: This step is energizing the on/off valves for all the low and high range synchros.
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Illustration 104 g06153825
Select "Forward Shift" to shift to "Synchro Mod ON" to energize Synchro Mod. Record values in Table 13.
Note: If Synchro Position is out of range, do not continue. Select "N" to restart test. If test fails 3 times, inspect for a hydraulic or mechanical problem.
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Illustration 105 g06153828
Select "Forward Shift" to shift to "Synchro Mod OFF" to de-energize Synchro Mod.
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Illustration 106 g06153835
Select "Forward Shift" to shift to "Neg MSR Sync". Record speeds in Table 13.
Note: Connect Tooling (U) Planetary Speed Sensor to Speed Sensor Input #1 or #2 to read Planetary Speed in Hz with the TA3.
Note: MSR - Motor Speed Ratio, Maximum Negative Swash Plate Position.
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Illustration 107 g06153839
Select "Forward Shift" to shift to "LoR Valv ON".
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Illustration 108 g06153840
Select "Forward Shift" to shift to "Command Sync Wav". Record values in Table 13.
Note: If Synchro Position is out of range, do not continue. Select "N" to restart test. If test fails 3 times, inspect for a hydraulic or mechanical problem.
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Illustration 109 g06153844
Select "Forward Shift" to shift to "Clutch B ON" to engage Clutch B. Record Clutch Pressure in Table 13.
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Illustration 110 g06153867
Select "Forward Shift" to shift to "Go to zero MSR". Record values in Table 13.
Note: Connect Tooling (U) Planetary Speed Sensor to Speed Sensor Input #1 or #2 to read Planetary Speed in Hz with the TA3.
Note: MSR - Motor Speed Ratio, Centered Swash Plate Position.
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Illustration 111 g06153872
Select "Forward Shift" to shift to "Go to +ve point". Record values in Table 13.
Note: Connect Tooling (U) Planetary Speed to Speed Sensor Input #1 or #2 to read Planetary Speed in Hz with the TA3.
Note: Connect Tooling (U) Output Speed Sensor #1 and #2 to Speed Sensor Input #1 and #2 to read output speed with the TA3.
Note: Maximum Positive Swash Plate Position.
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Illustration 112 g06153878
Select "Forward Shift" to shift to "HiR Valv ON" to energize valves.
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Illustration 113 g06153918
Select "Forward Shift" to shift to "Command Sync Wav". Record values in Table 13.
Note: If Synchro Position is out of range, do not continue. Select "N" to restart test. If test fails 3 times, inspect for a hydraulic or mechanical problem.
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Illustration 114 g06153921
Select "Forward Shift" to shift to "Clutch B OFF" to de-energize Clutch B. Record Clutch Pressure in Table 13.
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Illustration 115 g06153930
Select "Forward Shift" to shift to "All Synchros ON" to energize all synchro On/Off valves..
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Illustration 116 g06153934
Select "Forward Shift" to shift to "Synchro Mod ON" to energize Synchro Mod. Record values in Table 13.
Note: If Synchro Position is out of range, do not continue. Select "N" to restart test. If test fails 3 times, inspect for a hydraulic or mechanical problem.
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Illustration 117 g06153940
Select "Forward Shift" to shift to "Synchro Mod OFF" to de-energize Synchro Mod. Record values in Table 13.
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Illustration 118 g06153941
Select "Forward Shift" to shift to "End" to go to a de-energized state. Record values in Table 13.
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Illustration 119 g06153947
Select "N" to return to neutral position.

Forward Test

The Forward Test will accelerate the transmission through Low Forward range, shift into High Forward range, and end when the Aux Synchro successfully engages.

Adjust input speed to 800 rpm.
Adjust Backpressure Valve (case drain ball valve) to restrict flow and de-stroke the steering pump. Allow for a small amount of oil flow from the discharge to cool the pump. Make sure a small amount of oil is leaving the case drain.
Adjust Transmission Sump Oil Valve (H) and Transmission Sump Drain Valve (K) to maintain oil level.
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Illustration 120 g06154779
Select "CVT-1-e-Forward".
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Illustration 121 g06154810
Select "Transmission Test".
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Illustration 122 g06154905
Select "Forward Shift" to shift to "All Syncros ON" to energize all synchro.
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Illustration 123 g06154906
Select "Forward Shift" to shift to "Syncro Mod ON" to energize Synchro Mod. Record values in Table 14.
Note: If Synchro Position is out of range, do not continue. Select "N" to restart test. If test fails 3 times, inspect for a hydraulic or mechanical problem.
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Illustration 124 g06154910
Select "Forward Shift" to shift to "Syncro Mod OFF" to de-energize Synchro Mod.
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Illustration 125 g06154914
Select "Forward Shift" to shift to "Neg MSR Sync". Record values in Table 14.
Note: Connect Tooling (U) Planetary Speed Sensor to Speed Sensor Input #1 or #2 to read Planetary Speed with the TA3.
Note: MSR - Motor Speed Ratio, Maximum Negative Swash Plate Position.
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Illustration 126 g06154916
Select "Forward Shift" to shift to "LOF Valv ON" to energize valves.
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Illustration 127 g06154918
Select "Forward Shift" to shift to "Command Sync Wav". Record values in Table 14.
Note: If Synchro Position is out of range, do not continue. Select "N" to restart test. If test fails 3 times, inspect for a hydraulic or mechanical problem.
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Illustration 128 g06154921
Select "Forward Shift" to shift to "Clutch A ON" to engage Clutch A. Record values in Table 14.
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Illustration 129 g06154923
Select "Forward Shift" to shift to "Accel to Zero MSR". Record values in Table 14.
Note: Connect Tooling (U) Planetary Speed Sensor to Speed Sensor Input #1 or #2 to read Planetary Speed in Hz with the TA3.
Note: MSR - Motor Speed Ratio, Centered Swash Plate Position.
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Illustration 130 g06154927

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Illustration 131 g06154931
Select "Forward Shift" to shift to "Accel to +ve Pt". Record values in Table 14.
Note: Connect Tooling (U) Planetary Speed Sensor to Speed Sensor Input #1 and #2 to read Planetary Speed in Hz with the TA3.
Note: Connect Tooling (U) Output Speed Sensor #1 and #2 to Speed Sensor Input #1 and #2 to read output speed with the TA3.
Note: Maximum Positive Swash Plate Position.
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Illustration 132 g06154932
Select "Forward Shift" to shift to "HiF Valv ON" to energize valves.
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Illustration 133 g06154935
Select "Forward Shift" to shift to "Command Sync Wav". Record values in Table 14.
Note: If Synchro Position is out of range, do not continue. Select "N" to restart test. If test fails 3 times, inspect for a hydraulic or mechanical problem.
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Illustration 134 g06154953
Select "Forward Shift" to shift to "Clutch B ON" to engage Clutch B. Record values in Table 14.
Note: Noise will occur. With both clutches engaged, the variator is forced to the exact shift point which will build some hydraulic pressure in the hydrostatic loop. This will not cause damage to the transmission.
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Illustration 135 g06154955
Select "Forward Shift" to shift to "Clutch A OFF" to de-energize Clutch A. Record values in Table 14.
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Illustration 136 g06154958
Select "Forward Shift" to shift to "LoF-HiR Valv ON" to energize valves.
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Illustration 137 g06154964
Select "Forward Shift" to shift to "Syncro Mod ON" to energize Synchro Mod. Record values in Table 14.
Note: If Synchro Position is out of range, do not continue. Select "N" to restart test.
Note: LoF and Aux engaged at the same time will lockup the transmission and force the input shaft to zero speed. Make sure that the LoF synchro is neutralized before continuing.
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Illustration 138 g06154971
Select "Forward Shift" to shift to "Syncro Mod OFF" to de-energize Synchro Mod. Record values in Table 14.
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Illustration 139 g06154974
Select "Forward Shift" to shift to "Raise Pump B Cur". Record values in Table 14.
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Illustration 140 g06154975
Select "Forward Shift" to shift to "Aux Syncro ON" to engage Aux Synchro. Record values in Table 14.
Note: If Synchro Position is out of range, do not continue. Select "N" to restart test .If test fails 3 times, inspect for a hydraulic or mechanical problem.
Note: Charge Flow delta is "Raise Pump B Cur" minus "Aux Syncro ON". If Charge Flow is out of range, inspect for an internal hydraulic leak.
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Illustration 141 g06154978
Select "Forward Shift" to shift to "Clutch B OFF" to de-energize Clutch B. Record values in Table 14.
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Illustration 142 g06154981
Select "Forward Shift" to shift to "Neut Aux Syncro". Record values in Table 14.
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Illustration 143 g06154987
Select "Forward Shift" to shift to "HiF-LoR Valv ON" to energize valves.
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Illustration 144 g06154991
Select "Forward Shift" to shift to "Syncro Mod ON" to energize Synchro Mod. Record values in Table 14.
Note: If Synchro Position is out of range, do not continue. Select "N" to restart test. If test fails 3 times, inspect for a hydraulic or mechanical problem.
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Illustration 145 g06154996
Select "Forward Shift" to shift to "Syncro Mod OFF" to de-energize Synchro Mod. Record values in Table 14.
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Illustration 146 g06154999
Select "Forward Shift" to shift to "End" to go to a de-energized state. Record values in Table 14.

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 15.
Remove the transmission from the test bench if the test bench oil supply is within specifications.

Transmission Bench Test Data Sheet

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

Harness Test

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Table 6
Harness Test	Solenoid Name	Expected Value	Actual Value
Solenoid 1	LoF On/Off Solenoid	PASS	________________
Solenoid 2	HiR On/Off Solenoid	PASS	________________
Solenoid 3	LoR On/Off Solenoid	PASS	________________
Solenoid 4	HiF On/Off Solenoid	PASS	________________
Solenoid 5	Pump A	PASS	________________
Solenoid 6	Pump B	PASS	________________
Solenoid 7	Synchro Mod	PASS	________________
Solenoid 8	Aux Synchro	PASS	________________
Solenoid 9	Clutch A	PASS	________________
Solenoid 10	Clutch B	PASS	________________

Note: HiF = High Forward

Note: HiR = High Reverse

Note: LoF = Low Forward

Note: LoR = Low Reverse

Sensor Test

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Table 7
Sensor Test
Record Channels	Expected Value	Actual Value
LoF-HiR Position	20-84% Duty Cycle	________________
LoR-HiF Position	20-84% Duty Cycle	________________
Aux Position	48-56% Duty Cycle	________________
Loop A Pressure	5-7% Duty Cycle	________________
Loop B Pressure	5-7% Duty Cycle	________________
Trans Oil Temp	1991-249 Ohms 35° ± 25°C (63° ± 45°F)	________________
Flushing Oil Temp	3268-107 Ohms 42.5° ± 42.5°C (76.5° ± 76.5°F)	________________
Input Speed	0 ± 25 Hz	________________
Planetary Speed	0 ± 25 Hz	________________
Output Speed 1	0 ± 25 Hz	________________
Output Speed 2	0 ± 25 Hz	________________

Note: Make sure you have the low range selected on your multi meter when measuring Duty Cycle.

Start Up / Warm Up

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Table 8
Start Up Test		Immediately After Startup	After Warmed to 550 Ohms
Input Speed	800 ± 20 rpm 455 ± 12 Hz	________________	________________
Charge Pressure⁽¹⁾	2620 ± 69 kPa (380 ± 10 psi)	________________	________________
Lube Pressure⁽¹⁾	172 ± 103 kPa (25 ± 15 psi)	________________	________________
Gerotor Flow	57 ± 8 L/min (15 ± 2 US gpm)	________________	________________
Charge Flow	14 ± 6 L/min (3.5 ± 1.5 US gpm)	________________	________________
Lube Flow	45 ± 8 L/min (12 ± 2 US gpm)	________________	________________
Trans Oil Temp	1991-249 Ohms 35° ± 25°C (63° ± 45°F)	________________	________________
Flushing Oil Temp	3268-107 Ohms 42.5° ± 42.5°C (76.5° ± 76.5°F)	________________	________________
Pump A Pressure	0 ± 35 kPa (0 ± 5 psi)	________________	________________
Pump B Pressure	0 ± 35 kPa (0 ± 5 psi)	________________	________________
Synchro Mod Pressure	0 ± 35 kPa (0 ± 5 psi)	________________	________________
LoF Pressure	0 ± 35 kPa (0 ± 5 psi)	________________	________________
HiR Pressure	0 ± 35 kPa (0 ± 5 psi)	________________	________________
LoR Pressure	0 ± 35 kPa (0 ± 5 psi)	________________	________________
HiF Pressure	0 ± 35 kPa (0 ± 5 psi)	________________	________________
Clutch A Pressure	0 ± 35 kPa (0 ± 5 psi)	________________	________________
Clutch B Pressure	0 ± 35 kPa (0 ± 5 psi)	________________	________________
Aux Pressure	0 ± 35 kPa (0 ± 5 psi)	________________	________________

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⁽¹⁾	Critical Value

Lube Relief Test

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Table 9
Input Speed 800 ± 20 rpm
Input Speed	800 ± 20 rpm 455 ± 12 Hz	________________
Lube Pressure	138 ± 69 kPa (20 ± 10 psi)	________________
Trans Oil Temp	550-249 Ohms 50° ± 10°C (90° ± 18°F)	________________
Gerotor Flow	57 ± 8 L/min (15 ± 2 US gpm)	________________
Charge Flow	14 ± 6 L/min (3.5 ± 1.5 US gpm)	________________
Lube Flow	45 ± 8 L/min (12 ± 2 US gpm)	________________
Input Speed 1000 ± 20 rpm
Input Speed	567 ± 12 Hz	________________
Lube Pressure	193 ± 62 kPa (28 ± 9 psi)	________________
Trans Oil Temp	550-249 Ohms 50° ± 10°C (90° ± 18°F)	________________
Gerotor Flow	68 ± 8 L/min (18 ± 2 US gpm)	________________
Charge Flow	15 ± 6 L/min (4 ± 1.5 US gpm)	________________
Lube Flow	57 ± 6 L/min (15 ± 1.5 US gpm)	________________
Input Speed 1200 ± 20 rpm
Input Speed	683 ± 12 Hz	________________
Lube Pressure	227 ± 75 kPa (33 ± 11 psi)	________________
Trans Oil Temp	550-249 Ohms 50° ± 10°C (90° ± 18°F)	________________
Gerotor Flow	83 ± 8 L/min (22 ± 2 US gpm)	________________
Charge Flow	19 ± 6 L/min (5 ± 1.5 US gpm)	________________
Lube Flow	68 ± 6 L/min (18 ± 1.5 US gpm)	________________
Input Speed 1400 ± 20 rpm
Input Speed	794 ± 12 Hz	________________
Lube Pressure	255 ± 83 kPa (37 ± 12 psi)	________________
Trans Oil Temp	550-249 Ohms 50° ± 10°C (90° ± 18°F)	________________
Gerotor Flow	98 ± 8 L/min (26 ± 2 US gpm)	________________
Charge Flow	19 ± 6 L/min (5 ± 1.5 US gpm)	________________
Lube Flow	79 ± 6 L/min (21 ± 1.5 US gpm)	________________
Input Speed 1600 ± 20 rpm
Input Speed	906 ± 12 Hz	________________
Lube Pressure	296 ± 103 kPa (43 ± 15 psi)	________________
Trans Oil Temp	550-249 Ohms 50° ± 10°C (90° ± 18°F)	________________
Gerotor Flow	114 ± 11 L/min (30 ± 3 US gpm)	________________
Charge Flow	23 ± 6 L/min (6 ± 1.5 US gpm)	________________
Lube Flow	87 ± 8 L/min (23 ± 2 US gpm)	________________
Input Speed 1700 ± 20 rpm
Input Speed	957 ± 12 Hz	________________
Lube Pressure	324 ± 124 kPa (47 ± 18 psi)	________________
Trans Oil Temp	550-249 Ohms 50° ± 10°C (90° ± 18°F)	________________
Gerotor Flow	121 ± 11 L/min (32 ± 3 US gpm)	________________
Charge Flow	23 ± 4 L/min (6 ± 1 US gpm)	________________
Lube Flow	93 ± 8 L/min (24.5 ± 2 US gpm)	________________

Synchro Test

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Table 10
Position		Expected Value	Actual Value
LoF-HiR ON	No Valves to Check
Synchro Mod Pulse	LoF-HiR Position	48.5 – 53.5% Duty Cycle	________________
Ramp up Mod	Charge Flow	14 ± 6 L/min (3.5 ± 1.5 US gpm)	________________
	Synchro Mod Pressure	2634 ± 221 kPa (382 ± 32 psi)	________________
	LoF Pressure	2634 ± 221 kPa (382 ± 32 psi)	________________
	HiR Pressure	2634 ± 221 kPa (382 ± 32 psi)	________________
Mod OFF	No Valves to Check
LoF-HiR OFF	LoF-HiR Position	48.5 — 53.5% Duty Cycle	________________
	Charge Flow	14 ± 6 L/min (3.5 ± 1.5 US gpm)	________________
	Syn Mod Pressure	0 ± 35 kPa (0 ± 5 psi)	________________
	LoF Pressure	0 ± 35 kPa (0 ± 5 psi)	________________
	HiR Pressure	0 ± 35 kPa (0 ± 5 psi)	________________
	Charge Flow Δ	0 ± 4 L/min (0 ± 1 US gpm)	________________
LoR-HiF ON	No Valves to Check
Synchro Mod Pulse	LoR-HiF Position	48.5 — 53.5% Duty Cycle	________________
Ramp up Mod	Charge Flow	14 ± 6 L/min (3.5 ± 1.5 US gpm)	________________
	Syn Mod Pressure	2634 ± 221 kPa (382 ± 32 psi)	________________
	LoR Pressure	2634 ± 221 kPa (382 ± 32 psi)	________________
	HiF Pressure	2634 ± 221 kPa (382 ± 32 psi)	________________
Mod OFF	No Valves to Check
LoR-HiF OFF	LoR-HiF Position	48.5 — 53.5% Duty Cycle	________________
	Charge Flow	14 ± 6 L/min (3.5 ± 1.5 US gpm)	________________
	Synchro Mod Pressure	0 ± 35 kPa (0 ± 5 psi)	________________
	LoR Pressure	0 ± 35 kPa (0 ± 5 psi)	________________
	HiF Pressure	0 ± 35 kPa (0 ± 5 psi)	________________
	Charge Flow Δ	0 ± 4 L/min (0 ± 1 US gpm)	________________

Note: Make sure you have the low range selected on your multi meter when measuring Duty Cycle.

Note: Charge Flow delta is "Ramp up Mod" minus "LoF-HiR OFF". If Charge Flow delta is out of range, inspect for an internal hydraulic leak.

Note: Charge Flow delta is "Ramp up Mod" minus "LoR-HiF OFF". If Charge Flow delta is out of range, inspect for an internal hydraulic leak.

Clutch Test

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Table 11
Position		Expected Value	Actual Value
LoF-HiR ON	No Valves to Check
Synchro Mod Pulse	LoF-HiR position	48.5 — 53.5% Duty Cycle	________________
	LoR-HiF position	48.5 — 53.5% Duty Cycle	________________
	Aux Synchro position	48 — 56% Duty Cycle	________________
LoF-HiR OFF	No Valves to Check
Clutch A ON	Clutch A Pressure	2551 ± 138 kPa (370 ± 20 psi)	________________
Clutch A ON	Charge Flow	14 ± 6 L/min (3.5 ± 1.5 US gpm)	________________
Clutch A OFF	Clutch A Pressure	0 ± 35 kPa (0 ± 5 psi)	________________
	Charge Flow	14 ± 6 L/min (3.5 ± 1.5 US gpm)	________________
	Charge Flow Δ	0 ± 4 L/min (0 ± 1 US gpm)	________________
Clutch B ON	Clutch B Pressure	2551 ± 138 kPa (370 ± 20 psi)	________________
Clutch B ON	Charge Flow	14 ± 6 L/min (3.5 ± 1.5 US gpm)	________________
Clutch B OFF	Clutch B Pressure	0 ± 35 kPa (0 ± 5 psi)	________________
	Charge Flow	14 ± 6 L/min (3.5 ± 1.5 US gpm)	________________
	Charge Flow Δ	0 ± 4 L/min (0 ± 1 US gpm)	________________

Note: Make sure you have the low range selected on your multi meter when measuring Duty Cycle.

Note: Charge Flow delta is "Clutch A ON" minus "Clutch A OFF". If Charge Flow delta is out of range, inspect for an internal hydraulic leak.

Note: Charge Flow delta is "Clutch B ON" minus "Clutch B OFF". If Charge Flow delta is out of range, inspect for an internal hydraulic leak.

Variator Test

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Table 12
Position		Expected Value	Actual Value
Pump A ON	Pump A Pressure	2620 ± 207 kPa (380 ± 30 psi)	________________
	Loop A	8.2–13.1% Duty Cycle	________________
	Loop B	8.2–11.3% Duty Cycle	________________
	Planetary Speed	1175 ± 75 Hz	________________
	Charge Flow	19 ± 11 L/min (5 ± 3 US gpm)	________________
Pump A OFF	Pump A Pressure	0 ± 35 kPa (0 ± 5 psi)	________________
	Loop A	8.2–11.3% Duty Cycle	________________
	Loop B	8.2–11.3% Duty Cycle	________________
	Planetary Speed	700 ± 50 Hz	________________
	Charge Flow	13 ± 6 L/min (3.5 ± 1.5 US gpm)	________________
	Charge Flow Δ	0 ± 4 L/min (0 ± 1 US gpm)	________________
Pump B ON	Pump B Pressure	2620 ± 207 kPa (380 ± 30 psi)	________________
	Loop A	8.2–11.3% Duty Cycle	________________
	Loop B	8.2–13.1% Duty Cycle	________________
	Planetary Speed	250 ± 50 Hz	________________
	Charge Flow	19 ± 11 L/min (5 ± 3 US gpm)	________________
Pump B OFF	Pump B Pressure	0 ± 35 kPa (0 ± 5 psi)	________________
	Loop A	8.2–11.3% Duty Cycle	________________
	Loop B	8.2–11.3% Duty Cycle	________________
	Planetary Speed	700 ± 50 Hz	________________
	Charge Flow	13 ± 6 L/min (3.5 ± 1.5 US gpm)	________________
	Charge Flow Δ	0 ± 4 L/min (0 ± 1 US gpm)	________________

Note: Make sure you have the low range selected on your multi meter when measuring Duty Cycle.

Note: Charge Flow delta is "Pump A ON" minus "Pump A OFF". If Charge Flow is out of range, inspect for an internal hydraulic leak.

Note: Charge Flow delta is "Pump B ON" minus "Pump B OFF". If Charge Flow is out of range, inspect for an internal hydraulic leak.

Reverse Test

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Table 13
Position		Expected Value	Actual Value
All Synchros ON	No Valves to Check
Synchro Mod ON	LoF-HiR Position	48.5-53.5% Duty Cycle	________________
	LoR-HiF Position	48.5-53.5% Duty Cycle	________________
	Aux Position	48-56% Duty Cycle	________________
Synchro Mod OFF	No Valves to Check
Neg MSR Sync Maximum Negative swash plate position.	Pump A Pressure	827 ± 138 kPa (120 ± 20 psi)	________________
Neg MSR Sync Maximum Negative swash plate position.	Planetary Speed	1080 ± 50 Hz	________________
LoR Valve ON	No Valves to Check
Command Sync Wav	LoF-HiR Position	48.5-53.5% Duty Cycle	________________
	LoR-HiF Position	20-26% Duty Cycle	________________
	Aux Position	48-56% Duty Cycle	________________
Clutch B ON	Clutch B Pressure	2551 ± 138 kPa (370 ± 20 psi)	________________
Go to zero MSR Centered swash plate position.	Pump A Pressure	0 ± 35 kPa (0 ± 5 psi)	________________
Go to zero MSR Centered swash plate position.	Planetary Speed	700 ± 50 Hz	________________
Go to +ve point Maximum Positive swash plate position.	Pump B Pressure	896 ± 138 kPa (130 ± 20 psi)	________________
	Planetary Speed	325 ± 50 Hz	________________
	Output Speed 1	1125 ± 50 Hz	________________
	Output Speed 2	1125 ± 50 Hz	________________
HiR Valve ON	No Valves to Check
Command Sync Wav	LoF-HiR Position	77-82% Duty Cycle	________________
	LoR-HiF Position	20-26% Duty Cycle	________________
	Aux Position	48-56% Duty Cycle	________________
Clutch B OFF	Clutch B Pressure	0 ± 35 kPa (0 ± 5 psi)	________________
All Synchros ON	No Valves to Check
Synchro Mod ON	LoF-HiR Position	48.5-53.5% Duty Cycle	________________
	LoR-HiF Position	48.5-53.5% Duty Cycle	________________
	Aux Position	48-56% Duty Cycle	________________
Synchro Mod OFF	Syn Mod Pressure	0 ± 35 kPa (0 ± 5 psi)	________________
End	Pump B Pressure	0 ± 35 kPa (0 ± 5 psi)	________________

Note: Make sure you have the low range selected on your multi meter when measuring Duty Cycle.

Note: MSR - Motor Speed Ratio.

Forward Test

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Table 14
Position		Expected Value	Actual Value
All Synchros ON	No Valves to Check
Syncro Mod ON	LoF-HiR Position	48.5-53.5% Duty Cycle	________________
	LoR-HiF Position	48.5-53.5% Duty Cycle	________________
	Aux Position	48-56% Duty Cycle	________________
Syncro Mod ON	No Valves to Check
Neg MSR Sync Maximum Negative swash plate position.	Pump A Pressure	827 ± 138 kPa (120 ± 20 psi)	________________
Neg MSR Sync Maximum Negative swash plate position.	Planetary Speed	1080 ± 50 Hz	________________
LoF Valv ON	No Valves to Check
Command Sync Wav	LoF-HiR Position	20-26% Duty Cycle	________________
	LoR-HiF Position	48.5-53.5% Duty Cycle	________________
	Aux Position	48-56% Duty Cycle	________________
Cutch A ON	Clutch A Pressure	2551 ± 138 kPa (370 ± 20 psi)	________________
Accel to zero MSR Centered swash plate position.	Pump A Pressure	0 ± 35 kPa (0 ± 5 psi)	________________
Accel to zero MSR Centered swash plate position.	Planetary Speed	700 ± 50 Hz	________________
Accel to +ve point Maximum Positive swash plate position.	Pump B Pressure	896 ± 138 kPa (130 ± 20 psi)	________________
	Planetary Speed	325 ± 50 Hz	________________
	Output Speed 1	950 ± 50 Hz	________________
	Output Speed 2	950 ± 50 Hz	________________
HiF Valv ON	No Valves to Check
Command Sync Wav	LoF-HiR Position	20-26% Duty Cycle	________________
	LoR-HiF Position	77-82% Duty Cycle	________________
	Aux Position	48-56% Duty Cycle	________________
Clutch B ON	Clutch B Pressure	2551 ± 138 kPa (370 ± 20 psi)	________________
Clutch A OFF	Clutch A Pressure	0 ± 35 kPa (0 ± 5 psi)	________________
Clutch A OFF	Clutch B Pressure	2551 ± 138 kPa (370 ± 20 psi)	________________
LoF-HiR Valv ON	No Valves to Check
Syncro Mod ON	LoF-HiR Position	48.5-53.5% Duty Cycle	________________
	LoR-HiF Position	77-82% Duty Cycle	________________
	Aux Position	48-56% Duty Cycle	________________
Syncro Mod OFF	No Valves to Check
Raise Pump B Cur	Planetary Speed	262 ± 15 Hz	________________
	Pump B Pressure	1000 ± 138 kPa (145 ± 20 psi)	________________
	Charge Flow	13 ± 6 L/min (3.5 ± 1.5 US gpm)	________________
Aux Syncro ON	LoF-HiR Position	48.5-53.5% Duty Cycle	________________
	LoR-HiF Position	77-82% Duty Cycle	________________
	Aux Position	68-75% Duty Cycle	________________
	Charge Flow	13 ± 6 L/min (3.5 ± 1.5 US gpm)	________________
	Charge Flow Δ	0 ± 4 L/min (0 ± 1 US gpm)	________________
Clutch B OFF	Clutch B Pressure	0 ± 35 kPa (0 ± 5 psi)	________________
Neut Aux Syncro	LoF-HiR Position	48.5-53.5% Duty Cycle	________________
	LoR-HiF Position	77-82% Duty Cycle	________________
	Aux Position	48-56% Duty Cycle	________________
HiF-LoR Valv ON	No Valves to Check
Syncro Mod ON	LoF-HiR Position	48.5-53.5% Duty Cycle	________________
	LoR-HiF Position	48.5-53.5% Duty Cycle	________________
	Aux Position	48-56% Duty Cycle	________________
Syncro Mod OFF	Syn Mod Pressure	0 ± 35 kPa (0 ± 5 psi)	________________
End	Pump B Pressure	0 ± 35 kPa (0 ± 5 psi)	________________

Note: Make sure you have the low range selected on your multi meter when measuring Duty Cycle.

Note: MSR - Motor Speed Ratio.

Note: Charge Flow delta is "Raise Pump B Cur" minus "Aux Syncro ON". If Charge Flow is out of range, inspect for an internal hydraulic leak.

Contamination Control

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Table 15
ISO Particle Count	Sample the test bench oil supply. *ISO 4406 is 16/13 or better	________/________Particle Count

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Table 16
____________________________________________________ Technician	__________________________________________________ Supervisor

Caterpillar Information System:

D6K2 Track-Type Tractor Machine Systems Piston Pump (Winch) - Remove and Install

336 and 336 GC Excavator Additional Messages

D6K2 Track-Type Tractor Machine Systems Fuel Tank - Remove and Install

D6N Track-Type Tractor Blades (Flexxaire Fan) - Inspect

Fuel System Cleanliness on Certain C4.2, C4.4, C6.4, and C6.6 Engines {1250, 1261, 1290} Fuel System Cleanliness on Certain C4.2, C4.4, C6.4, and C6.6 Engines {1250, 1261, 1290}

Procedure to Improve Fuel Injectors on Certain Machine Engines {1100, 1126, 1250, 1251, 1290} Procedure to Improve Fuel Injectors on Certain Machine Engines {1100, 1126, 1250, 1251, 1290}

New Bracket for Tilt Cylinder Hose Is Now Available on Certain 988K Large Wheel Loaders {5057, 5104} New Bracket for Tilt Cylinder Hose Is Now Available on Certain 988K Large Wheel Loaders {5057, 5104}

854K Wheel Dozer General Information (Hydraulic System)

Diesel Exhaust Fluid Quality Sensors May Have Fault Codes on Certain Tier 4 Final Engines {108H, 108K, 1439} Diesel Exhaust Fluid Quality Sensors May Have Fault Codes on Certain Tier 4 Final Engines {108H, 108K, 1439}

992K Wheel Loader Hydraulic System

An Improved Axle Pressure Relief Fitting is Now Used on All 924K, 926M, 930K, and 930M Small Wheel Loaders {3260, 3278} An Improved Axle Pressure Relief Fitting is Now Used on All 924K, 926M, 930K, and 930M Small Wheel Loaders {3260, 3278}

992K Wheel Loader Oil Filter (Hydraulic)

336 and 336 GC Excavator Fire Extinguisher Location

An Improved Bolt Tightening Procedure for the Critical Joints Is Now Used on All Excavators {4050, 4164, 5459, 7063} An Improved Bolt Tightening Procedure for the Critical Joints Is Now Used on All Excavators {4050, 4164, 5459, 7063}

Improved Transmission Drive Shaft Now Used on AD55B and AD60 Underground Articulated Trucks {3030} Improved Transmission Drive Shaft Now Used on AD55B and AD60 Underground Articulated Trucks {3030}

New Procedure to Prevent the Product Link Elite Hybrid Assets From De-registering is Now Available For Certain Wheel Loaders {7606, 7620} New Procedure to Prevent the Product Link Elite Hybrid Assets From De-registering is Now Available For Certain Wheel Loaders {7606, 7620}

336 and 336 GC Excavator Specifications

966M and 972M Wheel Loaders Power Train, Steering, Braking, Hydraulic & Machine Systems Electrohydraulic Control - Mounting

An Installation Procedure For A New Air Hose Is Available On Certain D6R2 Track-Type Tractors {1071} An Installation Procedure For A New Air Hose Is Available On Certain D6R2 Track-Type Tractors {1071}

336 and 336 GC Excavator Fuel Transfer Pump (Refueling) - If Equipped

New Ejector Cylinder Seal Installation Tooling Now Available for Underground Articulated Ejector Trucks {0699, 5305} New Ejector Cylinder Seal Installation Tooling Now Available for Underground Articulated Ejector Trucks {0699, 5305}

320GC, 320 and 323 Excavators Machine Systems Bucket - Remove and Install

320GC, 320 and 323 Excavators Machine Systems Bucket Linkage - Remove and Install

3512E Tier 4 Final Engines for Land Electric Drilling Flywheel




Illustration 31	g06155663
Left: Gerotor Flow Right: Charge Flow




Illustration 45	g06183957
19 - 190 L/min (5 - 50 US gpm) Gerotor (out)




Illustration 49	g06183962
5 - 57 L/min (2 - 15 US gpm) Charge Flow (in)




Illustration 50	g06156143
19 - 190 L/min (5 - 50 US gpm) Lube (in)




Illustration 51	g06156147
(28) LoR Pressure (Low Reverse) (29) HiF Pressure (High Forward)




Illustration 52	g06156163
(30) Clutch A Pressure (31) Aux Synchro Pressure (32) Clutch B Pressure




Illustration 53	g06156172
(33) HiR Pressure (High Reverse) (34) LoF Pressure (Low Forward)




Illustration 55	g06156200
(36) Pump A Pressure (37) Synchro Mod Pressure (38) Pump B Pressure (39) Charge Pressure




Illustration 66	g06150959
Example of Clutch A solenoid unplugged




Illustration 5	g06155188




Illustration 6	g06155189




Illustration 7	g06155444




Illustration 8	g06155448